How to adjust the polishing machine tool for optimal results?

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In mechanical manufacturing, the presence of burrs is an inevitable outcome of various machining processes when materials are transformed into components. Regardless of the chosen manufacturing technique, burrs come in different sizes but cannot be eliminated. Therefore, further post-processing is required to remove these burrs. However, it is important to note that the process of deburring itself generates new burrs, leading to a repetitive cycle. Thus, this article's discussion of deburring techniques is limited to surface deburring for flat panel parts.

Deburring Techniques for Flat Panel Parts:

Most flat panel parts are formed through cutting and stamping processes, which can be further classified into oxygen, plasma, laser, ultra-high-pressure water jet, electrolytic, and tool cutting. Among these methods, the cutting quality of oxygen and plasma cutting is generally the poorest, resulting in an abundance of slag and flash on the part surfaces. Additionally, the cut section often exhibits severe oxidation. For parts with such characteristics, the requirement is typically to remove the slag and flash, which can be achieved using a dry belt grinding machine. This process involves scratching the entire surface of the workpiece to eliminate slag and flash. However, this method cannot remove the oxidation layer from the cut section and often results in significant edge collapse.

For users with higher demands, in addition to removing slag and flash, it is necessary to completely remove the oxidation layer from the cross-sectional area and achieve a uniform edge. Ordinary belt grinding machines are no longer sufficient to meet these requirements.

Advanced Deburring Technologies:

The most advanced deburring technology available today is the double-sided automatic belt deburring machine, equipped with various types of belts to accommodate different needs:

1. Strong steel ball belts for removing slag and flash.

2. Sanding belts for regrinding and edge refinement.

3. Filament belts for precision grinding.

4. Steel wire belts for rust removal and cleaning.

Utilizing a combination of scraping, filing, and grinding principles, the elastic nature of the belts allows for targeted edge processing with minimal force applied to the flat surface. This results in effective deburring without damaging the surface, making it highly suitable for processing galvanized and film-coated plates. Furthermore, due to its elastic processing principle, the belts can reach deep into the cross-section of the workpiece, effectively removing the oxidation layer. Laser and water jet-cut parts typically have high precision and minimal burrs, and many manufacturers may not perform deburring processes. However, for users with high demands, deburring remains a crucial step. The double-sided automatic deburring machine offers superior processing quality, high efficiency, and cost-effectiveness, surpassing the capabilities of 20 skilled deburring workers. It can handle thicknesses ranging from 1mm to thicker materials, and by simply changing the appropriate belt, different materials can be processed with excellent results. This processing technique is equally applicable to flat panel parts produced through general stamping, progressive die stamping, and hydraulic processing, provided that the workpiece falls within the machine's specifications.

Challenges for Contoured and Precision Stamped Parts:

Unlike flat panel parts, precision stamped parts with contoured surfaces are not suitable for ordinary belt deburring machines or double-sided automatic deburring machines. These parts typically have smaller dimensions and fall outside the processing range of the aforementioned machines. In such cases, a planetary end-face grinding deburring machine is required. This machine is equipped with a dedicated conveyor belt and a magnetic conveying bed. Depending on the size of the burrs, it can be configured with one sanding head and two to three planetary end-face grinding heads. This configuration ensures perfect deburring for precision-stamped parts while maintaining their original dimensional accuracy. Different materials may require the use of separate grinding discs and belts.

For flat panel parts with deeper recessed surfaces, such as milled aircraft rib plates, where the cavity depth is considerable, none of the aforementioned machines can perform the necessary deburring tasks. In this case, a planetary wire brush roller deburring machine is the ideal solution. This machine employs a planetary revolution mechanism to drive six radially arranged wire brush rollers for high-speed bidirectional self-rotation. The workpiece is transported through the grinding heads via a vacuum conveyor belt, allowing for a complete and comprehensive deburring process on all sides of the workpiece. This machine can even reach depths of up to 40mm within open cavities, achieving a uniform and smooth deburring effect.

Adjusting the polisher tool effect is essential to achieve optimal deburring results for different types of work-pieces. Depending on the characteristics of the workpiece, various deburring techniques and machines are available, each with its advantages and capabilities. By selecting the appropriate deburring technology and making necessary adjustments, manufacturers can effectively remove burrs, oxidation layers, and other imperfections, improving the overall quality and appearance of their products. Embracing advanced deburring techniques and equipment ensures efficient and precise manufacturing processes, ultimately leading to enhanced customer satisfaction and competitiveness in the industry.