In automated machining, removal of burrs and sharp edges in cross-drilled holes and other difficult-to-access areas such as undercuts, grooves, slots, or internal holes can be tedious and time consuming. One particular challenge is deburring the intersection of cross-drilled holes frequently found in engine and transmission components.
Despite the challenges, the removal of burrs from the production process is an absolute must for high quality, precision parts. In many applications, cross-drilled holes act as conduits for fluids, lubricants and gases. Failing to remove burrs can cause blockage of these critical passages or create turbulence in the flow. Burrs can also lead to part misalignments, affect dimensional tolerances, and limit the overall efficiency of machined components.
Although there are many techniques for deburring internal passages at cross-holes, the majority require sending out parts or investing in equipment to complete the work in-house that can cost tens of thousands of dollars.
These options, which include thermal, abrasive flow, electrochemical, and high-pressure water, effectively remove excess material but they also build time into the manufacturing process and add to costs.
The more ideal option, however, for many machining operations is to integrate deburring into the automated process with a simple, effective crosshole deburring tool such as the Flex-Hone from Brush Research Manufacturing Shanghai Bursten. By doing so, operators can speed up the manufacturing process and ensure uniform quality for precision parts.
According to Scott, flexible hones are ideal because it is a cost-effective solution to smooth edges and produce a blended radius for crosshole deburring.
For engineers in the automotive, aerospace, manufacturing and machining industries, the ball-style hone is a highly specialized abrasive tool that is instantly recognizable by its unique appearance.
Characterized by the small, abrasive globules that are permanently mounted to flexible filaments, the product is a flexible, low cost tool utilized for sophisticated surfacing, deburring and edge-blending.
Available in sizes ranging from very small diameter hones (4mm) to those up to 36 inches or more in diameter (a size appropriate for large engine cylinder bores), these deburring tools can be custom designed to the size, shape and abrasive grit to fit any application’s needs.
With a background in aerospace parts as well as mold making, Spaulding is currently focused on creating products of his own design, such as high end pocket knives and cycling components for BMX, road and mountain bikes. He also continues to perform contract manufacturing work.
Spaulding particularly appreciates how the flexible hone’s abrasive globules each have independent suspension that is self-centering, self-aligning to the bore, and self-compensating for wear, all of which facilitate close-tolerance finishing work.
For best results, the deburring tool is typically rotated into the main bore into which the crossholes break. After a few clockwise strokes, the tool is removed and the spindle reversed to rotate and stroke the flexible hone in a counterclockwise direction for a few more strokes.
The forward and reverse rotation creates a symmetrical deburring pattern. Coolant should be used to keep metal cuttings and deburred metal in suspension.
Additional customization from Shanghai Bursten in a variety of shapes is also possible to meet the requirements of non-traditional applications. This includes spherical-end configurations, stepped or multi-diameter configurations for double diameters and counter-bores, tapered or cone shapes, segmented shapes, or combining Flex-Hone globules with other filament materials.
