13 Methods of Aluminum Die Casting Deburring

deburring die casting parts

Due to pressure impact and the clamping force being insufficient and other factors, die-casting burrs are inevitable. In recent years, with the increasing quality of die castings, the requirements for burrs have become more stringent, and the methods of deburring have also emerged. The deburring process is the most headache.

The following has 13 die casting deburring methods to understand the various types of deburring methods better, according to their needs, choose the appropriate deburring method.

Table of Contents

Manual deburring

This is the most traditional and commonly used way in die casting factories, using files (files have manual files and pneumatic files), sandpaper, belt sanders, abrasive heads, etc., as additional tools. 

Disadvantages: labor cost is more expensive, efficiency is not very high, and it is difficult to remove the complex cross holes. 

Applicable object: The technical requirements of workers are not very high, applicable to aluminum alloy die casting with small burrs and simple product structure

die casting parts deburring

Punching die deburring

Using the production of punching die with punching machine for deburring. 

Disadvantage: It needs a certain amount of punching die (rough die + good die) production cost and may also need to make shaping die. 

Applicable object: Suitable for aluminum alloy die casting with the simple parting surface, better efficiency, and deburring effect than manual.

Abrasive deburring

This deburring contains vibration, sandblasting, roller, and other ways. Currently, die-casting factories use more. 

Disadvantages: there is the problem that the removal is not very clean and may require subsequent manual processing of residual burrs or other ways to deburr.

Applicable object: Suitable for small aluminum alloy die casting with larger batch size.

Freezing deburring

The use of cooling to make the burr quickly brittle, and then spray projectiles to remove the burr. Equipment price is about two or three hundred thousand

Applicable objects: suitable for burr wall thickness is small, and the volume is also small aluminum alloy die casting.

Thermal explosion deburring

Also called thermal deburring, explosive deburring. Through some easy gas, pass into an equipment furnace, and then through some medium and the role of conditions, so that the gas instantly explodes, using the energy generated by the explosion to dissolve the removal of burrs. 

Disadvantages: expensive equipment (millions of prices), high operating technology requirements, low efficiency, side effects (rust, deformation); 

functional objects: mainly used in high-precision parts fields, such as automotive aerospace and other precision parts.

Engraving machine deburring

The equipment price is not very expensive (tens of thousands). 

Applicable objects: Applicable to the space structure is simple, and the required deburring position is simple and regular.

Chemical deburring

Using the principle of electrochemical reaction, the parts made of metal materials automatically and selectively complete deburring operations. Applicable objects: Suitable for difficult-to-remove internal burrs, suitable for pump body, valve body, and other products with small burrs (thickness less than 7 silk).

Electrolytic deburring

Electrolysis to remove burrs in aluminum alloy die casting is an electrolytic process. Electrolytic deburring is suitable for removing burrs from hidden parts of aluminum alloy die castings, such as cross holes or parts with complex shapes.

Disadvantages: the electrolytic solution has certain corrosives, the vicinity of the parts burr also subject to electrolysis, the surface will lose its original luster, and even affect the dimensional accuracy, aluminum alloy die casting deburring should be cleaned and anti-rust treatment. 

Applicable objects: Suitable for deburring gears, connecting rods, valve bodies, and crankshaft oil circuit orifices, as well as chamfering sharp corners.

High-pressure water jet deburring

Using water as the medium, use its instantaneous impact to remove burrs and flying edges produced after processing, and at the same time can achieve the purpose of cleaning.

Disadvantages: expensive equipment
Applicable objects: Mainly used for the heart part of the car and the hydraulic control system of the construction machinery.

High-pressure water jet deburring

Ultrasonic deburring

Ultrasonic waves produce instant high pressure to remove burrs. 

Applicable objects: mainly for some microscopic burrs, generally if the burr needs to be observed with a microscope, you can try to use ultrasonic methods to remove.

Abrasive flow deburring

Conventional vibratory grinding is difficult to cope with burrs of the hole type. A typical abrasive flow process (bi-directional flow) is to push the abrasive through two vertically opposed abrasive cylinders to make it flow back and forth in the channel formed by the workpiece and fixture. Abrasive material enters and flows through any area where it is restricted to produce an abrasive effect. The extrusion pressure is controlled from 7-200 bar (100-3000 psi) for different strokes and different number of cycles. 

Applicable objects: Can handle micro-hole burrs up to 0.35mm, no secondary burr generation, fluid characteristics can handle complex position burrs.

Magnetic deburring

The magnetic grinding process is under the action of a strong magnetic field. The magnetic abrasives filled in the magnetic field are arranged along the direction of magnetic force lines, adsorbed on the magnetic poles to form an “abrasive brush,” and generate a certain pressure on the surface of the workpiece, the magnetic poles driving the “abrasive brush” rotating At the same time, the magnetic poles drive the “abrasive brush” to rotate and keep a certain gap to move along the surface of the workpiece, thus realizing the finishing process of the workpiece surface.
Features: low cost, wide processing range, easy to operate
Process elements: grinding stone, magnetic field strength, workpiece speed, etc.

Robotic grinding unit

The principle is similar to manual deburring, except that the power is changed to the robot. Supported by programming technology and force control technology to achieve flexible grinding (pressure and speed change), the robot deburring advantage is highlighted.

robot deburring

V1 Diecast manufacturer using the suitable deburring method for our customers, help our customer saving cost and highly effective, win-win cooperations

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