Gear Deburring with Power Brushes

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Hannah Roberts
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1 Gear Deburring wih Power es n n n Crimped Wire Wheels Kno Wire Wheels Nylox Wheels An Inroducion o Auomaing Deburring of Power Transmission Componens

Deburr for Qualiy & Performance Why Do Gears Need To Be Deburred? All cuing and shaping operaions produce some ype of burr or leave a sharp edge.

Even well-aached, heavy burrs can loosen from he paren edge, eiher during assembly or in acual operaion. These chips are hen free o ravel hrough he power ransmission sysem and damage componens.

Radiusing eliminaes edge defecs, minimizes sress risers and conribue o beer mesh and lower operaing noise beween individual componens in a driverain.

Alhough power ransmission componens are available in a wide variey of configuraions, in-service performance is ofen deermined by edge qualiy. Why Are es Ideal Tools For Deburring Gears?

The moving filamens of a brush concenrae heir collecive kineic energy on he edges of a par.

2 Deburr for Qualiy & Performance Why Do Gears Need To Be Deburred? All cuing and shaping operaions produce some ype of burr or leave a sharp edge. On power ransmission componens such as gears, hese undesirable by-producs are especially roublesome. Even well-aached, heavy burrs can loosen from he paren edge, eiher during assembly or in acual operaion. These chips are hen free o ravel hrough he power ransmission sysem and damage componens. Under operaing condiions, sharp edges become areas where inernal sresses concenrae and failures become more likely. Radiusing eliminaes edge defecs, minimizes sress risers and conribue o beer mesh and lower operaing noise beween individual componens in a driverain. In summary, removing burrs and sharp edges improves he qualiy, performance and reliabiliy of power ransmission componens. Alhough power ransmission componens are available in a wide variey of configuraions, in-service performance is ofen deermined by edge qualiy. Why Are es Ideal Tools For Deburring Gears? n es Do No Aler Par Geomery Power-driven brushing ools have been used for removing burrs and sharp edges for over half of a cenury. The moving filamens of a brush concenrae heir collecive kineic energy on he edges of a par. Couple his characerisic wih he compliance ha is inheren in a brush and he resul is a produc ha is able o remove undesirable edge defecs wihou alering he geomery of a par. This abiliy makes hem ideal for deburring complex power ransmission componens ha are manufacured o close olerances and igh specificaions. n es Are Ideal For Auomaion Alhough brushes are radiionally viewed as grea ools for offhand applicaions, heir use in auomaed applicaions has also proven o be effecive and economical. Their durabiliy and flexibiliy complemen he efficiency and consisency of semiauomaic or fully auomaic equipmen. A properly designed auomaed brush deburring process usually coss only a few cens per par while having he abiliy o mee oher producion requiremens. Alhough gear and sprocke manufacurers were among he firs o adop he use of auomaed brush deburring processes, here is sill a grea deal of confusion abou equipmen design, machine se-up, and media selecion even wihin he power ransmission indusry

Selec a Suiable Type Burr Classificaion And Filamen Selecion Burr size, shape and orienaion are criical in he selecion of brush fill maerial.

Class One Class Two Class Three Ofen called "micro-burrs" because hey can only be ob served under magnificaion, Class One burrs appear as sharp edges o he unaided eye.

Class Two burrs can usually be removed by a pencil ip. Class Five Burrs in his group are relaively small in size, bu are well-aached o he paren edge.

The primary difference is ha Class Four burrs are larger wih slighly hicker roos. Burrs in his class are very large wih exremely hick, rigid roos.

n Nylon Abrasive Filamen es are bes undersood by hinking of hem as a collecion of flexible files. Each nylon filamen conains housands of abrasive grains.

3 Selec a Suiable Type Burr Classificaion And Filamen Selecion Burr size, shape and orienaion are criical in he selecion of brush fill maerial. These phoos show a variey of burrs wih differen characerisics. They are classified in a way which describes he difficuly of removal in qualiaive erms. Class One Class Two Class Three Ofen called "micro-burrs" because hey can only be ob served under magnificaion, Class One burrs appear as sharp edges o he unaided eye. Grinding operaions are a common source for his burr formaion. Class Four Feaher burrs are readily visible wihou magnificaion; ypically small in size and characerized by hin roos. Class Two burrs can usually be removed by a pencil ip. Class Five Burrs in his group are relaively small in size, bu are well-aached o he paren edge. Because of his, a significan amoun of mechanical energy mus be applied o remove Class Three burrs. Like Class Three burrs, he burrs in his class are well-aached. The primary difference is ha Class Four burrs are larger wih slighly hicker roos. Burrs in his class are very large wih exremely hick, rigid roos. Class Five burrs differ from he convenional definiion of a burr because hey consis of displaced base maerial ha is sill fully aached o he paren edge. n Nylon Abrasive Filamen es are bes undersood by hinking of hem as a collecion of flexible files. Each nylon filamen conains housands of abrasive grains. Alhough hese filamens conain he same size grains as oher abrasive producs, he flexible nylon carrier does no forcefully apply hem o fla surfaces. However, when hey encouner an edge, hese abrasive grains ac like he eeh on a file, removing burrs and generaing small edge radii. Due o he flexibiliy of he nylon brisles, he ulimae aggression of abrasive filamen brushes can be somewha limied. Tradiional Nylox brushes feauring filamens wih silicon-carbide abrasive grains are capable of removing Class One and mos Class Two burrs. Burr-Rx brushes feauring filamens conaining an engineered ceramic abrasive grain are more cos-effecive ools capable of removing large Class Two and Class Three burrs as well as many Class Four burrs. In addiion o differen abrasive grains and gri sizes, brush media feauring differen filamen sizes, fill densiies, and rim lenghs are available o ailor he brushing acion o he requiremens of a paricular applicaion. n Crimped And Kno Wire es work hrough an impac-driven process similar o sand blasing. The focused velociy of millions of sharp wire ips sriking an edge wihin a shor period of ime srips away burrs and peens sharp edges. es wih crimped wire offer a more complian brushing acion han kno wire brushes which maximize he impac of he wire ips on he work. Because wire brushes can focus a grea deal of mechanical energy on an edge, hey are bes suied for removing large Class Three and Class Four burrs. Alhough Class Five burrs can someimes be removed wih paricularly aggressive brushes, cuing ools or abrasive producs are ofen beer suied for removing hese heavy burrs. For Applicaion Assisance Call: APPS (2777) 3

Choose he Proper Orienaion Burr Locaion and Presenaion Burr locaion deermines he proper orienaion of he brush o he par.

Produc life expecancy is direcly dependen on he amoun of peneraion ino he face. Minimizing brushing pressure reduces filamen faigue in wire-filled brushes and filamen wear in Nylox brushes.

Raher, i peens hem agains he face of he gear - see A.

Finally, he peneraion ha is required o place he wire ips on he roo diameer of he gear decreases he brush life due o excessive wire faigue. In conras, Se-up II produces more desirable resuls.

4 Choose he Proper Orienaion Burr Locaion and Presenaion Burr locaion deermines he proper orienaion of he brush o he par. The brush filamens mus have direc access o he burr, and he paren edge mus be oriened properly relaive o he direcion of filamen movemen. orienaion also affecs producion economics. Produc life expecancy is direcly dependen on he amoun of peneraion ino he face. Minimizing brushing pressure reduces filamen faigue in wire-filled brushes and filamen wear in Nylox brushes. The following phoos depic wo approaches for deburring a small spur gear. Se-up I is no desirable for several reasons. Firs, he brush does no deach all of he burrs. Raher, i peens hem agains he face of he gear - see A. Secondly, he variaion in peneraion ino he brush face produces Se-up I - No Recommended excessive radii on he ips of he gear eeh and performs inadequae work on he roos. Finally, he peneraion ha is required o place he wire ips on he roo diameer of he gear decreases he brush life due o excessive wire faigue. In conras, Se-up II produces more desirable resuls. Using his echnique, he wire ips srike each ooh edge as he par roaes. The burrs are easily removed because he direcion of filamen movemen aacks hem a he roo and bends hem away from he paren edge. The amoun of peneraion ino he brush face is minimized and does no vary. Thus, brush life is maximized while a more consisen radius is generaed on he eeh. Se-up II - Recommended Resul I A Resul II es are mos effecive a deburring edges ha are perpendicular o he direcion of filamen movemen. The following phoos illusrae his poin using a helical gear wih wo common burr configuraions. In Case I, he primary burr is on he side of he ooh. Based on his posiion, brush heads should be locaed as shown in Orienaion I. This brush posiion focuses maximum deburring acion on he sides of he gear eeh since hey are perpendicular o filamen movemen. The primary burrs in Case II are near he roos of he eeh. To remove burrs in his locaion, he brushes need o be moved o he oriena ion shown in Orienaion II. By reposiioning he brushes, he conac poin beween he brush and he par is changed and more energy is applied o he roos of he gear eeh. Case I Orienaion I Case II Orienaion II Conac Poin Conac Poin 4

5 Selec Appropriae Parameers Prior o selecing he operaing parameers for a paricular deburring applicaion, brush size mus be deermined. This is because he velociy a which he filamens srike he work is a funcion of boh spindle speed and produc diameer. In general, larger diameer brushes are preferred, even when dealing wih small pars, because hey lower consumablecos-per-par and increase producion sabiliy. The only excepion o his rule occurs when a small diameer brush is required o access an edge due o he par geomery. Alhough power-driven brushes are available in oher configuraions such as disc, cup, and end brushes, hese produc ypes are no frequenly used in gear deburring applicaions because of heir roary, mulidirecional naure. The unidirecional naure of wheel brushes allows hem o focus a larger amoun of mechanical energy on a arge edge wihin a relaively shor ime. The following able liss he recommended operaing parameers for wheel brushes based on diameer and fill maerial. Wheel es and Operaing Parameers Size 1"-2" 3"-4" 6" 8" 10" 12" 14" Wire Speed 20,000 15,000 5,000 3,450 2,500 2,000 1,750 Wire DOI u Nylox Speed 5,000 3,000 1,750 1,400 1,200 1, Nylox DOI u *Power 1/4 hp 1/3 hp 1/2 hp 3/4 hp 1 hp 1-1/4 hp 1-1/2 hp Minimum Spindle Diameer 1/4" 3/8" 1/2" 5/8" 3/4" 1" 1-1/4" *Noe: Power recommendaions are saed per one inch of engaged brush face. u Deph of Inerference. Because wire-filled brushes work hrough an impac-driven mechanism, hey should be used a higher speeds and wih a minimum amoun of peneraion. Excessive peneraion ino he face no only reduces brush life, i also decreases he conac beween he wire ips and he work. Nylox brushes, on he oher hand, require lower speeds and greaer amouns of peneraion. This allows he filamens o smoohly file across he arge edges. Troubleshooing The able in he preceding secion provides general guidelines for he majoriy of applicaions. If hey are no effecive in a paricular applicaion, he following able conains recommendaions for increasing and decreasing aggression. Problem no aggressive enough is oo aggressive Wire Recommendaions Selec a brush wih larger diameer wire fill Selec a brush wih shorer rim and higher fill densiy Selec a brush wih kno wire versus crimped wire Increase operaing speed Selec a brush wih smaller diameer wire fill Selec a brush wih longer rim and lower fill densiy Selec a brush wih crimped wire versus kno wire Decrease operaing speed Nylox Recommendaions Selec a brush conaining a more aggressive filamen Selec a brush wih shorer rim and higher fill densiy Increase brushing pressure and deph of inerference Increase brushing ime Selec a brush conaining a less aggressive filamen Selec a brush wih longer rim and lower fill densiy Decrease brushing pressure and deph of inerference Decrease brushing ime 5 For Applicaion Assisance Call: APPS (2777)

Use Qualiy Media for he Lowes Cos Weiler offers he mos complee line of power brushes in he indusry as well as he echnical experise o aid wih your selecion of he bes produc and process o mee your

For addiional produc selecion or assisance wih your gear deburring problem, call our Applicaions Holine oll-free a 888-299-APPS (2777).

020 1/2"-3/8" 08024 3" Abrasive Nylon Wheels Filamen Arbor Iem Dia./Gri Hole No..035/180SC 1/2"-3/8" 31084.026/120CG* 1/2"-3/8" 86164.

6 Use Qualiy Media for he Lowes Cos Weiler offers he mos complee line of power brushes in he indusry as well as he echnical experise o aid wih your selecion of he bes produc and process o mee your needs. The following is a condensed selecion of Weiler brushes available for your deburring applicaions. For addiional produc selecion or assisance wih your gear deburring problem, call our Applicaions Holine oll-free a APPS (2777). es for ChamferMaic and Redin Gear Deburring Machines " Crimped Wire Wheels.008 1/2"-3/8" /2"-3/8" " Kno Wire Wheels /2"-3/8" /2"-3/8" " Abrasive Nylon Wheels Filamen Arbor Iem Dia./Gri Hole No..035/180SC 1/2"-3/8" /120CG* 1/2"-3/8" /120CG* 1/2"-3/8" *Burr-Rx ceramic-abrasive filamen 4" Crimped Wire Wheels /2"-3/8" /2"-3/8" " Kno Wire Wheels /2"-3/8" /2"-3/8" " Abrasive Nylon Wheels Filamen Arbor Iem Dia./Gri Hole No..035/180SC 1/2"-3/8" /120CG* 1/2"-3/8" /120CG* 1/2"-3/8" *Burr-Rx ceramic-abrasive filamen es for ACME and Osborn Gear Deburring Machines " Kno Wire Wheels.014 2" " " 09790*.020 2" 09800* *Heavy-duy 90-kno consrucion 14" Abrasive Nylon Wheels Filamen Arbor Iem Dia/Gri Hole No..026/120CG* 2" /120CG* 2" /80CG* 2" /80CG* 2" *Burr-Rx ceramic-abrasive filamen Recommended es for New Applicaions 12" Kno Wire Wheels 12" Crimped Wire Wheels 12" Crimped Nylox Wheels For he full offering of Weiler power brushes, abrasives, and mainenance producs, please refer o our Soluions Resource Guide, visi our websie or call our Applicaions Holine a o discuss your requiremens wih a produc specialis /4" /4" " 09870* *Heavy-duy 66-kno consrucion /4" /4" /4" See above for an assormen of 14" wheels ha would be recommended for new applicaions Filamen Arbor Iem Dia./Gri Hole No..035/180SC 2" /120SC 2" /80SC 2" /120CG* 2" /120CG* 2" /80CG* 2" *Burr-Rx ceramic-abrasive filamen Weiler Corporaion. All Righs Reserved. Form Reorder No.: WC357 Rev LP

Dimensions. Model Number. Electrical connection emitter. Features. Electrical connection receiver. Product information. Indicators/operating means

Dimensions. Model Number. Electrical connection emitter. Features. Electrical connection receiver. Product information. Indicators/operating means OBE-R-SE Dimensions.8.8 ø..75 7.5 6. 5 6.7 4.9 4. 5.9 ø.6 Model Number OBE-R-SE Elecrical connecion emier Thru-beam sensor wih m fixed cable Feaures 45 cable oule for maximum mouning freedom under exremely