Cleaning and Deburring of Casted Parts

Deburring is the process of removing excess material on the surface of manufactured parts, whether ferrous or non-ferrous, which can pose handling hazards or compromise the structural integrity of the material. Usually, deburring occurs after machining, although the casting process also exposes surface imperfections that require deburring.

It is a pre-finishing process that involves subjecting the manufactured part to various methods of removing deformities once die casting is completed.Deburring can be a time-consuming process, prompting many companies to outsource or altogether skip it. However, there is a crucial reason why deburring remains vital to manufacturing die-cast parts.

Why is Deburring Necessary?

While some manufacturers may try to avoid deburring due to its associated costs and time requirements, we at Eurobalt Engineering ensure that the parts you receive are nearly flawless. Additionally, we recognize and prioritize the significance of effective deburring. This process is essential for the durability and longevity of the finished product. Below, we present some key reasons why deburring is a necessary step in the manufacturing process.

Prevent fractures
When burrs are left unchecked, there might be uneven surface pressure and increased stress in certain areas. No matter the application of the parts produced, stress and uneven pressure is never a good sign and can cause fracture, all because of burrs.
Increase fatigue life
Fatigue life or fatigue strength is the limit to which a part can perform a specified function before reaching failure. Unchecked burrs can hinder the stress cycle of a part resulting in earlier than expected failure.
Avoid corrosion
Deburring helps remove the burrs but it also assists in making the surface area even. Due to an uneven surface, there is a possibility of corrosion which does not benefit the longevity of the casted parts.
Dampen static charge
Uneven surfaces and burrs have higher tendency of holding static charge. Not removing burrs can result in the retention and dispersion of static charge.
Decrease friction
Casted parts primarily form the cover of other movable parts. The movement of parts produces friction but when two surfaces are not clean and have burrs the movement is hindered, there is an increased level of friction and heat production becomes a massive issue, all because a small burr has not been removed.
Safe handling
Cropping of metal or non-metal parts may result in cuts and accidents. As for handling a casted part, hidden burrs may cause difficulty in handling. Splints and protrusions can cause some serious damage, so cleaning and deburring are necessary to avoid those incidents.

Types of Deburring Techniques

There are five distinct techniques for deburring casted parts that are widely utilized, each with its own specialized area. All five are capable of delivering exceptional deburring outcomes, and thus, your selection should be based on your preference for one of the five techniques.

Manual deburring
The earliest and most common deburring technique used in manufacturing plants is manual deburring. By the name itself, it is probably clear that manual deburring is concerned with direct human effort in cleaning and deburring.

This technique is a tried and tested method since manufacturers have started surface treatment. It is an old, useful, extremely time-consuming, and also expensive technique of deburring. While manual deburring allows a level of flexibility, there is still the problem of manpower associated with the technique.
Thermal deburring
This technique is a fast and efficient way to target and eliminate multiple burrs at the same time. It is also useful in reaching difficultly accessible burrs. While the heat resistance capability of casted part should be kept in mind, thermal deburring can definitely get the job done by burning off burrs without causing structural damage.
Mechanical deburring
Another generally utilized method of deburring in a manufacturing plant is mechanical deburring. Similar to machining, mechanical deburring is a process where milling and grinding methods are used to even out the surface and get rid of burrs.

While machining is known for causing burrs, special tips and rotating plates attached to the machine can help grind the surface to a clean and burr-free finish. It is also a faster alternative to the manual deburring technique.
Electrochemical deburring
By the name it can be deduced that this technique is concerned with electricity and chemicals for the purposes of deburring. Something called “electro chemical machining” is used in some manufacturing plants to eliminate burrs.

Electricity with salt or glycol solution is used to attack and dissolve burrs without harming the surrounding parts. When precision is needed in elimination of burrs, then this technique comes in handy.
Cold deburring
While thermal deburring is concerned with burning off the burrs, the cold deburring technique breaks the burrs. The burrs are exposed to rapid cold temperatures and then the embrittled burrs are broken off by using a high-pressure spray. There is no loss of integrity of the casted part and the process can attack multiple burrs at the same time.

Some Ways to Avoid Deburring

Deburring is a time-consuming process that can result in loss of valuable time and manpower when working on the same manufactured tool. Although deburring is sometimes unavoidable, there are manufacturing techniques available to minimize burrs. Here are some ways to reduce burr creation and avoid deburring:

Down milling
There is a proven method of creating fewer burrs and in turn avoiding the deburring process, it is the down milling technique. When milling is done downwards on casted parts, there are fewer chances of burr formation.

With the help of down milling, the number and size of burrs are greatly reduced when compared to up milling.
Design
One of the major ways in which deburring can be avoided is by focusing on the design before the casting process can begin. The design should be done in such a way that extra milling and machining can be avoided.

Even if they cannot be avoided, the design of casted parts should be in such a way that burrs can be situated in areas that are easily accessible for burr removal. While deburring may not be avoidable here, the time loss is less significant when design aids the deburring process.
Avoiding unnecessary deburring
There is a simple way by which deburring can be reduced, not doing it all the time and for every single burr. During the manufacturing process, it should be recognized that when a burr is at the place where it will not cause friction and there is no discernable way it can cause harm, deburring should be avoided.

However, a manufacturer needs to be totally sure that the burr they are leaving behind will not cause any harm in the future. It is more of guess work, but unnecessary work should be avoidable if possible.
Managing the breakthrough process
One of the major reasons for creation of burrs in casted parts is the process of machining. Sometimes casted parts need to go through extra machining to make threads and drill holes in them, this is where burrs are created.

One of the ways burrs can be avoided or minimized during machining is managing breakthrough. When cutting tools break through the bottom of a casted part, that is when burrs are created. While breaking through the hole exit, the speed and angle of extrusion should be watched thoroughly. This will help in creation of smaller, thinner, and manageable burrs.

Eurobalt Provides Cleaned and Deburred Casted Parts

We specialize in die casting as one of the primary operations of our metalworking company. We manufacture die-casted products in different shapes and sizes, and based on client requirements, we offer surface finishing, coating, and painting services.

Furthermore, our factory is equipped with deburring machines to ensure that the die-casted parts are finished flawlessly. We provide a variety of techniques to our clients, and choose the best possible solution based on the materials used, resulting in near-perfect outcomes.

Working with us, you will have access to a comprehensive range of services including manufacturing, pre-finishing, and finishing all readily available under one roof. Outsourcing won’t be necessary as we manage every step of the production process for you. Simply send us your drawings, and we’ll take care of the rest.

Please pick up the phone and contact our sales department for assistance throughout the entire process, including post-delivery support. Alternatively, you may email us with a description of the parts you are casting, and we will gladly provide you with cleaned and deburred finished parts.

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