| Complex aluminum parts often leave behind burrs | | | | effectively. |
| during the manufacturing process. Burrs can be | | | | Therefore, if a part has consistent placement of burrs, |
| located deep within tough to reach holes, or in more | | | | a high-pressure direct spray system is appropriate. An |
| accessible locations along grooves. No matter where | | | | example of this can be found in an automotive |
| they are located, it is necessary to remove these | | | | transmission plant. An aluminum valve body, once |
| burrs before the product is finished. Hydro de-burring is | | | | milled, is left with a consistent roll over bore in the spool |
| a process that can the removal of these burrs more | | | | bore. A power brush cannot access the hole where |
| efficient, while also making that removal repeatedly | | | | the spur is located. A probing brush may be able to |
| consistent as well. | | | | access the burr, but there is the chance that it will |
| Hydro de-burring machines use high-pressure water | | | | damage the machined surface of the part and render |
| jets, that direct water at pressures ranging anywhere | | | | it scrap. |
| from 1,500 PSI to 7,500 PSI using from 5 to 30 GPM | | | | A high-pressure water stream can shoot into the hole |
| solution flow to knock away burrs at their root, leaving | | | | and knock the bore off with precision. It can then flush |
| the part burr free. These machines are able to break | | | | the burr out, and do no damage to the machined |
| off the burrs and blow away the residual chips, but | | | | surface. Assuming the burr is formed in the same spot |
| they are not a miracle solution to all problems. Hydro | | | | in the prior stages, the high-pressure water system will |
| de-burring cannot mechanically machine off the burrs, it | | | | deliver the best quality possible every time. |
| does not leave behind a smooth finish, nor does it | | | | With this quality comes a high cost. Properly |
| create rounded edges. The manufacturer will need to | | | | engineered high pressure deburr systems cost at least |
| continue whatever process they are using to achieve | | | | $500,000 or more. The high cost can be attributed to |
| those ends once the de-burring unit is installed. | | | | the purchased components and customer driven plant |
| Although a hydro de-burring unit is limited in its ability to | | | | safety regulations. Many of the parts necessary for a |
| accomplish the goals listed above, it is effective in | | | | high-pressure system can cost upwards of $5,000. |
| many other areas. For example, it effectively removes | | | | Hydro de-burr systems require parts such as: |
| heavy grease and oil. Also, high pressure spray | | | | -High Pressure Pump |
| impingement can take off paint and knock out | | | | -High Pressure nozzles and manifolds |
| embedded sand and dirt. Pockets of embedded chips | | | | -High Pressure tubing and hoses |
| are also removed from the part, along with solvents | | | | -Filtration |
| left over from the cleaning process. | | | | -Oil Separation |
| Hydro de-burring uses a system of hydraulically | | | | -Fixtures to hold part in place |
| powered rotary high pressure water jets, which shoot | | | | -Sound dampening measures |
| water at a straight, 0 degree angle. This allows the | | | | All of these parts can be expensive. However, if the |
| water to hit the part at a right angle, ensuring that the | | | | hydro de-burr system is able to remove burrs quicker |
| jets will travel into any hole on the part as deep as | | | | and easier than a wire brush system on a particular |
| possible. | | | | part, it is well worth the cost to invest in the unit. The |
| The effectiveness of hydro de-burring depends on | | | | guaranteed removal of burrs combined with the lack |
| three factors. First, the volume of water used. It must | | | | of damage to the part itself (wire brushes can remove |
| be enough to have the power to knock off the burrs. | | | | burrs but also inflict damage on the part) will help the |
| Second, the speed of the water propelled through the | | | | manufacturer recoup their initial investment through |
| jets must be sufficient. And finally, the thickness and | | | | production of high quality parts. |
| type of burr that is being attacked. The thinner the root | | | | The high pressure system comes in many different |
| of the burr, the more effective the process will be. | | | | types of machines. Manufacturers can pick from |
| Bigger burrs will require more water and higher | | | | robotic transfer, conveyorized pallet, rotating dial table, |
| pressures to be removed. A good test to determine if | | | | chain driven, belt driven, manual, and automated |
| the burr being removed is of the correct size is the | | | | machines, depending on the needs of their specific |
| pencil test. If a burr can be removed by a .5mm | | | | plant and part. They also include part drying and blow |
| diameter pencil lead that is 9.00mm long without | | | | off stations, to ensure that the part received when |
| damaging the lead itself, then the burr can be removed | | | | finished is clean, burr-free, and dry. |
| with high-pressure water. | | | | Hydro de-burring is especially popular within the |
| Hydro de-burring is an effective and efficient process, | | | | automotive industry. Producers of oil pumps, engine |
| but it is not ideally suited for all manufacturers. Not all | | | | blocks, valve bodies, transmission components, and |
| metal cutters leave burrs in the same location every | | | | crankshafts are among the users of hydro de-burring |
| time. In these cases, brushes and media tumblers are a | | | | units. Any company with a repeatable, consistent burr |
| better choice for the company. Hydro de-burring is | | | | production in their parts should consider a hydro |
| effective, but it should not automatically be considered | | | | system to make their production process better. If the |
| the best option. If the burr is not consistently placed, the | | | | money they will make from delivering a high-quality end |
| jets will not be able to remove the burr all the time. If it | | | | product is worth the cost of the machine, then it may |
| is, the hydro system will remove it consistently and | | | | be time to invest in a hydro-deburring unit. |