Complex aluminum parts often leave burrs during the manufacturing process. Burrs can be placed deep in hard-to-reach holes or in more accessible places along the grooves. No matter where they are, it is necessary to remove these burrs before finishing the product. Hydraulic deburring is a process that can remove these burrs more efficiently, while making the removal consistent repeatedly.
Hydraulic deburring machines use high-pressure water jets, which direct water at pressures ranging from 1,500 PSI to 7,500 PSI using a solution flow of 5 to 30 GPM to remove burrs at their root, leaving the part free of debris. burrs. These machines can break up burrs and remove residual chips, but they are not a silver bullet for all problems. Hydraulic deburring cannot mechanically remove burrs, does not leave a smooth finish or create rounded edges. The fabricator will need to continue whatever process it is using to achieve those ends once the deburring unit is installed.
Although a hydraulic deburring unit has a limited ability to achieve the goals listed above, it is effective in many other areas. For example, it effectively removes heavy grease and oil. Additionally, the impact of high-pressure spray can strip paint and remove encrusted grit and dirt. Pockets of embedded chips are also removed from the part, along with any solvents left over from the cleaning process.
Hydraulic deburring uses a system of hydraulically actuated high pressure rotating water jets, which shoot water at a right angle of 0 degrees. This allows the water to hit the part at a right angle, ensuring that the jets travel to any hole in the part as deep as possible.
The effectiveness of hydrodeburring depends on three factors. First, the volume of water used. It should be enough to have the power to remove the burrs. Second, the velocity of the water propelled through the jets must be sufficient. And finally, the thickness and type of burr that is being attacked. The thinner the root of the burr, the more effective the process will be. Larger chips will require more water and higher pressures to remove. A good test to determine if the burr to be removed is the correct size is the pencil test. If a burr can be removed with a 0.5mm diameter, 9.00mm long pencil lead without damaging the lead, then the burr can be removed with high pressure water.
Hydraulic deburring is an effective and efficient process, but it is not ideal for all manufacturers. Not all metal cutters leave burrs in the same place every time. In these cases, brushes and media cups are a better option for the company. Hydraulic deburring is effective, but should not automatically be considered the best option. If the flash is not laid evenly, the jets will not be able to remove the flash every time. If so, the hydraulic system will consistently and effectively remove it.
Therefore, if in addition to having uniform flash placement, a high pressure direct spray system is appropriate. An example of this can be found at an automotive transmission plant. An aluminum valve body, once milled, is left with a constant turning hole in the spool bore. An electric planer cannot access the hole where the spur is located. A probing planer can access the burr, but there is a chance that it will damage the machined surface of the part and turn it into scrap.
A high-pressure water jet can be shot into the hole and knock it down with precision. Then you can remove the burrs and not damage the machined surface. Assuming that the flash forms in the same place in the earlier stages, the high pressure water system will deliver the best possible quality every time.
With this quality comes a high cost. Properly designed high pressure deburring systems cost at least $500,000 or more. The high cost can be attributed to purchased components and customer driven plant safety regulations. Many of the parts needed for a high pressure system can cost upwards of $5,000. Hydraulic deburring systems require parts such as:
-High pressure pump
-High pressure nozzles and manifolds
-High pressure pipes and hoses
-Filtration
-Oil separation
-Accessories to keep the piece in place
-Sound dampening measures
All of these parts can be expensive. However, if the hydraulic deburring system can remove burrs faster and more easily than a wire brush system on a particular part, the unit is worth investing in. Guaranteed removal of burrs combined with no damage to the part itself (wire brushes can remove burrs but can also damage the part) will help the manufacturer recoup their initial investment by producing high quality parts.
The high pressure system comes on many different types of machines. Manufacturers can choose from robotic, pallet conveyor, turntable, chain driven, belt driven, manual and automated transfer machines depending on the needs of their specific plant and part. They also include parts drying and blowing stations, to ensure that the part received when finished is clean, burr-free and dry.
Hydraulic deburring is especially popular in the automotive industry. Producers of oil pumps, engine blocks, valve bodies, transmission components, and crankshafts are among the users of hydraulic deburring units. Any company with consistent, repeatable flash production on their parts should consider a hydroelectric system to improve their production process. If the money they will earn from delivering a high quality end product is worth the cost of the machine, then it may be time to invest in a hydrodeburring unit.