Here you will get a glimpse of our day-to-day operation: Process and project planning.
It is not possible to exactly define the mechanical capabilities for removing a burr. The following factors significantly affect the feasibility of a mechanical deburring process:
- Tool inserts and materials that can be used
- Component shapes and tolerances as well as accessibility
- The required deburring result
- Cycle times
- The experience of the programmer who maps the process onto the workpiece.
For example, in theory a deburring process can be implemented very easily because the contours are accessible and the deburring requirements achievable. In reality, however, the optimal cutting materials may not be used but alternative cutting materials cannot always achieve the desired deburring result.
Other examples are cast workpieces. Depending on the age of the mould, the component can be subject to large fluctuations within a tolerance range. If the mould is new, the tolerances are much smaller and a deburring process for these workpieces can be mapped much more easily. Casting variations increase along with the age of the mould. The process has to be adapted accordingly so that the same quality can be delivered across all stages of the mould.
Depending on their accessibility as well as the tool that is being used, drilled holes can be machined up to a certain degree. Generally, however, a mechanical deburring process always leaves behind a root burr. It can be removed in combination with a chemical or thermal deburring process. Depending on their accessibility, undercuts can partially be machined with special tools.
External contours can usually be machined without limitations. Generally, the only thing that has to be taken into account here is the tension of the component during machining.
The principle layout forms the basis. Surface and machining plans, the cycle time analysis and the selection of the correct tools complete the process.
The principle layout forms the basis for any project. It consists of defined placeholders. On the one hand, their graphic arrangement is supposed to provide customers with an overview. On the other hand, they are linked via parameters that allow us to capture dependencies and to illustrate them. The steel tube body of the cell frame forms the frame of each principle layout. Due to the modularisation strategy of WMS, this ensures the economic benefit of a modular system. On the other hand, it is possible to individually respond to a customer’s workpiece by choosing from different sizes and application parameters. We have refined this combination for more than 20 years, which is why it is ready for the overwhelming majority of customer applications. Different pieces can be selected from the modular system tool kit and placed within the defined tubular frame construction. We always rely on our established suppliers which have been our safe and dependable partners since our founding.
SURFACE AND MACHINING PLANS
Among the first data we need for the successful projection of the deburring application are the detailed component drawings as well as the STEP files. Without them, one of our deburring applications can only be performed with much greater effort. One of our process specialists imports the STEP files to the CAD program and, using an extensive cutting process, the contours that are to be deburred are mapped. Once the customer has approved this list, our process specialists go to work once again. A complete list of all required tools and a cycle time calculation are a basic part of our process engineering. In a follow-up step, optional deburring trials can be initiated that ensure process capability.
CYCLE TIME ANALYSIS
To a large degree, each production process is determined by its cycle time. That’s why downstream secondary processes that follow the machine production should not negatively influence cycle times. Unfortunately, the deburring process is too often not included in the production flow. That means that, right before the supposed completion, another significant effort has to be expended in order to achieve the required quality of the machined edges and contours that was defined in the production drawings. In many cases, this leads to corrections to the production specifications.
TIP: When planning your production, don’t forget the deburring process. Otherwise you could fall into a costly trap if otherwise unachievable qualities are demanded.
THE RIGHT TOOL
At WMS, you have the option of choosing from countless tools with different materials, shapes and coatings. Our employees know all of their advantages and disadvantages. That’s why we are taking a lot of time in this initial phase in order to discuss and coordinate these variables with our customers. We know that our customers obviously have made their own experiences and have their own favourites when it comes to selecting tools. We will gladly accommodate your wishes and provide advice that is founded on many years of experience.