In the die casting industry, whether zinc alloy die casting or aluminum alloy die casting, the principle is the same, and the difference between natural processes is not big. Die casting deburring is an inevitable process regardless of material. In recent years, with the increasing quality requirements of aluminum alloy die castings, people have more strict requirements on the burr of aluminum alloy die castings, and the burr method is getting closer and closer. The following is a brief introduction to the current deburring methods to facilitate you to choose different deburring methods for different products.
1. Manual deburring
This is a more traditional and commonly used method in aluminum alloy die casting plants. Files (files include manual files and pneumatic files), sandpaper, abrasive belt machine, grinding head, etc. are used as auxiliary tools.
Disadvantages: the labor cost is expensive, the efficiency is not very high, and it is difficult to remove complex cross holes.
Applicable object: aluminum alloy die castings with small burr and simple product structure.
2. Die deburring
Deburring shall be carried out by making die and punch press.
Disadvantages: it requires a certain production cost of stamping die (coarse die + fine die), and it may also need to make shaping die.
Applicable object: suitable for aluminum alloy die castings with simple parting surface. The efficiency and deburring effect are better than manual.
3. Grinding and deburring
Such deburring includes vibration, sand blasting, roller and other methods, which are widely used in aluminum alloy die casting plants at present.
Disadvantages: the removal is not very clean, and the residual burr may need to be treated manually or deburred in cooperation with other methods.
Applicable object: suitable for small aluminum alloy die castings with large batch.
4. Freeze deburring
The burr is rapidly embrittled by cooling, and then the burr is removed by shot blasting. The price of the equipment is about two or three hundred thousand;
Applicable object: suitable for aluminum alloy die castings with small burr wall thickness and small volume.
5. Thermal explosion deburring
It is also called thermal deburring and explosive deburring. Pass some natural gas into an equipment furnace, and then make the gas explode instantly through the action of some media and conditions, and use the energy generated by explosion to dissolve and remove burrs.
Disadvantages: expensive equipment (millions of prices), high technical requirements for operation, low efficiency and side effects (rust and deformation);
Applicable object: it is mainly used in some high-precision parts fields, such as precision parts such as automobile and aerospace.
6. Engraving machine deburring
The equipment price is not very expensive (tens of thousands).
Applicable object: it is suitable for simple spatial structure, simple and regular deburring position.
7. Chemical deburring
Based on the principle of electrochemical reaction, the deburring operation of parts made of metal materials can be completed automatically and selectively.
Applicable object: it is applicable to internal burrs that are difficult to remove, and small burrs (thickness less than 7 wires) of pump body, valve body and other products.
8. Electrolytic deburring
An electrochemical machining method for removing burr of aluminum alloy die casting by electrolysis. Electrolytic deburring is suitable for removing the burr of cross holes in hidden parts or parts with complex shape in aluminum alloy die castings. It has high production efficiency, and the deburring time generally takes only a few seconds to tens of seconds.
Disadvantages: the electrolyte is corrosive to a certain extent, and the parts near the burr are also affected by electrolysis, which will lose the original luster on the surface and even affect the dimensional accuracy. Aluminum alloy die castings shall be cleaned and antirust treated after deburring.
Applicable object: suitable for deburring gear, connecting rod, valve body and crankshaft oil circuit orifices, sharp corner rounding, etc.
9. High pressure water jet deburring
With water as the medium, its instantaneous impact force is used to remove the burrs and flash produced after processing, and the purpose of cleaning can be achieved at the same time.
Disadvantages: expensive equipment
Applicable object: it is mainly used for the hydraulic control system of automobile heart and construction machinery.
10. Ultrasonic deburring
Ultrasonic produces instantaneous high pressure to remove burrs.
Applicable object: mainly for some micro burrs. Generally, if the burrs need to be observed with a microscope, you can try to remove them by ultrasonic method.
11. Abrasive flow deburring
常规的振磨，对于孔洞类的毛刺难于应付，典型的磨粒流加工工艺（双向流），通过两个垂直相对的磨料缸推动磨料使其在工件和夹具形成的通道来回流动。磨料进入和流经通过被限制的任何区域都会产生研磨效果。挤出压力控制在7-200bar(100-3000 psi), 适用于不同的行程和不同的循环次数。
Conventional vibration grinding is difficult to deal with holes and burrs. The typical abrasive flow machining process (two-way flow) pushes the abrasive through two vertically opposite abrasive cylinders to make it flow back and forth in the channel formed by the workpiece and fixture. Abrasive entering and flowing through any restricted area will produce grinding effect. The extrusion pressure is controlled at 7-200bar (100-3000 psi), which is suitable for different strokes and different cycles.
Applicable object: it can handle 0.35mm microporous burr without secondary burr. The fluid characteristics can handle burr at complex positions.
12. Magnetic deburring
Magnetic abrasive machining is that under the action of a strong magnetic field, the magnetic abrasive filled in the magnetic field is arranged along the direction of the magnetic force line, adsorbed on the magnetic pole to form an "abrasive brush", and generates a certain pressure on the workpiece surface. While the magnetic pole drives the "abrasive brush" to rotate, it maintains a certain gap to move along the workpiece surface, so as to realize the finishing of the workpiece surface.
Features: low cost, wide processing range and convenient operation
Process elements: grindstone, magnetic field strength, workpiece speed, etc
13. Robot grinding unit
The principle is similar to manual deburring, only turning power into robot. With the support of programming technology and force control technology, flexible grinding (transformation of pressure and speed) is realized, and the advantages of robot deburring are highlighted.