|
 Deburring cross-drilled holes can be an expensive and time-consuming
operation. Electrochemical deburring (ECD) and thermal deburring may be
effective, but they require electricity or heat along with chemicals and
cleanups. ECD transmits electrical energy from an electrode to an electrolyte
chemical, which then dissolves the burrs. Thermal deburring requires a sealed,
pressurized chamber and a mixture of combustible gases. When this gaseous mixture is ignited, the
burrs are burned away. Sometimes, however, intense physical or chemical deburring
can damage small parts.
Burrs
are Worse
Damaging the parts you're trying to deburr is bad, but failing to
remove the burrs can be even worse. Burrs can cause part misalignments, affect
dimensional tolerances, and limit the overall efficiency of machined
components. In the case of cross-drilled holes, burrs can also block the flow
of cooling fluids, lubricants, and gases. Typically, these cross-drilled
intersections are found in critical auto parts such as engine
and transmissions components. For automakers and automotive suppliers, leaving
burrs in-place is not an option.
What's
the Best Way to Deburr?
Flexible honing uses a low-temperature abrading process to blend edges, improve
surface finish, and remove cut, torn, and folded metal. Because they are
oversized for any given bore, flex hones "pop out"
and into the intersection, removing the burrs without heat or electricity and
creating a clean radius at the transition edge.
Flex hones are also self-centering and self-aligning, which means
that these honing tools do not require complex setups. The only chemical that
is needed is a blend of
honing and lapping oils. Cleanup involves using a cylindrical wash brush with a detergent
and warm or hot water.
Although flexible honing is used in industry, there are also
applications for the at-home hobbyist with a hand drill. That's not the case
for electrochemical deburring (ECD) or thermal deburring equipment, of course, especially
if cost is a consideration.
Additional
Reading
Design World
- Tools Automate Deburring of Chamfered Through Holes
Manufacturing
Engineering - Better Ways to Deburr
Editor's Note: CR4 would like to thank BrushResearch for contributing this story, which originally appeared here.
| 
Re: Deburring Cross-Drilled Holes
