deburr aluminum but no tumbling or abrasive_ electro-chemical deburring vs. electropolishing vs....
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10/9/2015 Deburr Aluminum but No Tumbling or Abrasive? Electrochemical deburring vs. electropolishing vs. thermal vs. ion beam?
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Deburr Aluminum but No Tumbling or Abrasive?
An ongoing discussion from 1998 through 2015 . . .
(1998)
Q. I need a new process for deburring aluminum disc drive actuators. We currently use a tumble & blast method, but are lookingfor something new. We have looked into E.C.D. (electrochemical deburring) but it seems like a babysit process. I believe the rightprocess is tumble, but getting the right media and machine seems to be quite a chore. Please send any help.
Dick Smith Ft. Wayne Indiana
(1998)
A. I read your letter in finishing.com. I would like to introduce you to our process, but I also would need more informationfrom you regarding the size of the burrs. Our company has a process originally developed out of Sandia National Labs thatuses a rapidly pulsed high energy ion beam to modify surfaces on materials. This ion beam, IBEST, melts the surface to a 210micron depth at a pulse per second. The material then rapidly cools, freezing the near surface at a billion degrees per second.
10/9/2015 Deburr Aluminum but No Tumbling or Abrasive? Electrochemical deburring vs. electropolishing vs. thermal vs. ion beam?
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This creates a surface which varies according to material properties that is smoother, refines grain size, removes burrs,hardens, and various other effects in tool materials; this increases the performance of many tool steels and cemented carbidematerials This depends on how the customer wants the results to turn out in the end, but I think that we would successfullyremove your burrs created without changing the surface tolerance of the part.
Sincerely,
Kimberly Boucher Albuquerque, New Mexico
(1998)
A. Dick,You might look into thermal (flash) deburring. This technique uses an ignition front to melt, oxidize and vaporize burrs.
Donald M. MattoxSociety of Vacuum CoatersAlbuquerque, New Mexico
Ed. note: Mr. Mattox is the author of
8 June 1998
A. There are a couple of alternatives you can try: Depending on the alloy of aluminum, using an aluminum etchant to remove burrs might be feasible. A proprietary chemicalbright dip would give you a microetch with controlled surface removal.
Do you have the facilities to do something like this in house ? i.e., finishing line w/appropriate waste treatment? If not, aqualified aluminum/anodizing job shop probably would be a good idea.
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By tumbling, I'm assuming vibratory finishing. With the right media, and the right compound combination, you can accomplishdeburring, and brightening as well (this would be a more economical alternative if you have the equipment available or also alocal jobshop to provide this service.)
Good luck, I hope I have been of some help to you.
Sincerely,
David M. Weaver Toccoa, Georgia
Ed. note: With great sadness for his family we must advise that David lost his life to a car accident on Aug. 15, 2003.
(1998)
A. Dick:You might consider using electropolishing for this application. We have had some excellent results on certain disk drive parts.
adv. Please call us.
Regards,
Ed BayhaMetal Coating Process Corporation
Charlotte, North Carolina, USA
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(1998)
A. We have experience with several applications very similar to the one you described. One recent application was for thedeburring of an aluminum diecasting. The part was a computer guide arm (fixed magnetic disc). The best way to investigatewhether a mechanical processes would work for you is to have samples processed. The mechanical equipment we test in(vibratory, high energy disk and barrels) is usually the most economical alternative if a successful process can be developed.Often a simple change in tumbling or blast media can give you the answers you are looking for.
Mark Cantwell Huntingdon Valley, Pennsylvania
(1998)
A. Dick:The 1st assumption here is that your tumbling is vibratory finishing. The 2nd assumption is that the actuators can besuccessfully handled by standard vibratory equipment types (bowl or tub). That you do not have nesting problems where theparts will stick together during processing. The 3rd assumption is that there is a media available with the correct shape andsize to deburr the Aluminum actuators.
If you have the correct vibratory equipment to handle the actuators, I suggest you might consider using a liquid compound thatchemically accelerates burr removal and surface refinement. This can be 34 times faster than conventional processes. Themedia selection for chemically accelerated processes is usually non or low abrasive content plastic or ceramic media. Thesemedias have extremely low attrition rates and as such hold their geometry for a very long time.
Regards,Bill
Bill Boatright Morrisville, North Carolina
(1998)
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A. Dick,If I understand the part and problem, you probably are on the right track with tumbling (i.e., vibratory, tumble barrels or anothermass finishing operation). What you need is a fresh set of eyes on the situation. Your best bet is (if you haven't already doneso) to get a hold of you local metal finishing rep look in the phone book under "Metal Finishing Equipment and Supplies".They can come in, look at your problem and suggest several possible solutions. Also, get some sample parts to that personand/or the manufacturer(s) they recommend. The sheer volume of possible combinations of media, chemistry, machinery andprocesses is mindnumbing, so let someone else (who may already have experience with a part like yours) do the heavy lifting.
Dan Regan Cinnaminson, New Jersey
To minimize searching and thrashing, and to provide multiple points of view, Finishing.com combined formerly separate threads into the single dialog you arenow viewing. Please forgive any resultant repetition.
How to remove burrs from aluminium(2000)
Q. Hello, I am looking for a help how to remove burr from aluminium diecasting arm (computer part). Could any one give mesome advice what media and method should be used?
ng [last name deleted for privacy by Editor]
Malaysia
(2000)
A. There are several ways to remove burrs from aluminum part; however, the best methods for casting or machining parts isto use a deburring rotated drum with abrasive media (mostly use composite or other plastic intermediate material mixed withwater).
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Another way is to use a deburring machine using scotch bidirectional. Anyway, both methods are commonly used in aerospaceplants. Good luck....
eli yudkevich Israel
(2000)
A. Deburring small or delicate parts such as you seem to describe are usually now performed in compact centrifugalfinishing systems. These types of systems usually employ media that is quite small and can access the finer features ofsmaller parts such as yours.
Additionally, dry process media with microfine abrasive materials can be utilized to develop surface finishes that rival that onjewelry parts, if functional requirements should call for it.
David A. Davidson Bartlett, New Hampshire
(2000)
A. Previous comments are all good. However, what is your volume of production, what surface finish is required, and is costa factor. What equipment do you have in house, or do you need equipment? Need more information to properly direct you
AF KentonNova Finishing Sytems Inc. Hatboro, Pennsylvania
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Deburring aluminum disks without tumbling?(2002)
Q. Can you suggest an alternative to deburring aluminium disc's (pressed) other than tumbling.(chemicals, etc.) The disc is5005 H34 60 mm x 1.6 mm with writing stamped into it.
Regards,
Phil Martin Adelaide, South Australia
(2002)
A. There are about 5 major deburring methods in use. Three involve mechanical processes and abrasives. One involves theuse of temperature and the other is chemical. Each system has advantages and disadvantages. Rather than to go into detailsand/or advantages of each one, I suggest you refine your question either to the immediate problem or what you want toaccomplish.
AF KentonNova Finishing Sytems Inc. Hatboro, Pennsylvania
(2005)
Q. For 6061 aluminum, what are the technical options for electrochemical deburring? Do any of the processes result inhydrogen or process chemical entrapment in the surface? Is the resulting nearsurface a thin, dense aluminum oxide, or is there aporous, thick layer (similar to anodize)?
What are the differences between electrochemical deburring of aluminum and electropolishing of aluminum? Are they essentially
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the same process? Which is a better choice for microscopic burr removal?
Are there any industrystandards for chemical & electrochemical deburring of aluminum (e.g., ASTM or MIL)? Electropolishing ofaluminum?
Grant Kiehnemanufacturing Bloomfield, Connecticut, USA
To minimize searching and thrashing, and to provide multiple points of view, Finishing.com combined formerly separate threads into the single dialog you arenow viewing. Please forgive any resultant repetition.
Deburring perforated aluminum(2005)
Q. I've a small business building electrostatic loudspeakers in Malmoe, Sweden.The stators of these speakers are made from 1mm perforated aluminum, which I deburr by hand. This is very hard work andrestrict the numbers of speakers I can build. Is there a way of deburring with chemicals instead? I've heard of a Swedish techniqueusing no acids but glycol and low voltage, but thats all I know.
Jonas KarudLoudspeaker manufacturer Malmoe, Sweden
(2005)
A. I cannot answer your question regarding a chemical method of working your parts; however, there are some othermechanical methods that could be used. Your parts are thin, but not that thin that they couldn't be worked in a mass finishingsystem using a dry abrasive media. Proper sizing of equipment and the part are important to avoid distortion. If your parts areflat, it might also be possible to do this in a wide belt Timesaver.
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AF KentonNova Finishing Sytems Inc. Hatboro, Pennsylvania
(2005)
A. Electropolishing may easily solve your problem.
Jeffrey Holmes, CEF Spartanburg, South Carolina
August 27, 2008
A. I recommend the thermal deburring method.It's a high investment and built for high quantity.Regards,
Joern Struckmann Luhden, Germany
Need gentle chemical deburring method for Aluminum
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April 30, 2015 this entry appended to this thread by editor in lieu of spawning a duplicative thread
Q. Hi folks,I have a need to find a VERY gentle way of deburring a 6061T6 aluminum part. The blocks in question are about 1" x 1" x 3/4"with very fine features milled in them. There are channels ~~0.003" wide and "posts" in that channel about 0.001"w x 0.001"l x0.002" high. These posts have burrs on them that need to be removed.
The posts are so delicate that mechanical methods are out of the question. Even putting the part in a sonicator, or blowing withcompressed air, removed a number of the posts. There is probably a mechanical/stress/milling issue we need to resolve, but in themeantime, we are in search of a gentle chemical method that will remove the burrs without ripping them off.
My first thought was just to dip in NaOh for a few seconds and see what happens, but it occurs to me that there may be bettersolutions so I am asking here. We have a limited number of scrap parts to experiment with. It would be preferable to keep theseparts inhouse till we understand how to make a few of them.
Suggestions all greatly welcomed. Thanks! Dan
Daniel KollerPhysicist Charlottesville, Virginia ^ Privately contact this inquirer ^
May 2, 2015
Q. (I'm the original poster) I should add that we are eventually going to want to gold plate these aluminum blocks, so whilefor the initial tests, I'm willing to try anything to deburr, ultimately the process should leave a surface which is compatible withgold plating.
Daniel Koller [returning] Charlottesville, Virginia
May 3, 2015
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A. Hi DanielStandard chemical polishing processes may work but you will need to experiment.However, the size and complexity you describe sounds like a difficult milling job or a very simple photoetching job with noburrs to worry about.You could even mass produce them as, say,a 10x10 array and slice them after gold platingYou could even consider gold plating through a resist mask and using the gold as the etch resist
Geoff SmithHampshire, England
August 7, 2015 this entry appended to this thread by editor in lieu of spawning a duplicative thread
Q. CAN WE AVOID VIBRO PROCESS IN ALUMINIUM PRETREAT FOR ANODISING?
IF YES PLEASE LET ME KNOWTHANKS
VINAYAK JOSHImetals nanded maharashtra india
August 2015
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? Hi Vinayak. What is the alloy, the fabrication method, and approximate production rate? Why is avoiding this commonfinishing method important to you, and which (if any) of the above alternatives sound interesting? Thanks.
Regards,
Ted Mooney, P.E. RETfinishing.comPine Beach, New Jersey
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