XEBEC Brush TM for Surface. The Book. Advanced. Unique CNC deburring. Technical guidance for XEBEC's innova ve ceramic ber brush.

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1 XEBEC Brush TM for Surface The Book Advanced R Unique CNC deburring. Technical guidance for XEBEC's innova ve ceramic ber brush.

01. How does depth of cut influence tool wear? A light depth of cut is preferred in order to maximize brush life. This is especially true with lighter burr after end milling process. Depth of cut : 1.

2 01. How does depth of cut influence tool wear? A light depth of cut is preferred in order to maximize brush life. This is especially true with lighter burr after end milling process. Depth of cut : 1.0mm Depth of cut : 0.2mm Depth of cut 1.0mm Depth of cut 0.2mm 1 Depth of cut 1.0mm The test result shows the wear is 40μm aer 20 passes(2μm/1pass). Depth of cut 0.2mm There was very small tool wear(too small to measure) with depth of cut 0.2mm aer 20 passes. Test condions Test piecejis Aluminium 5052(DIN EN AW-5052) Tools usedφ10 end mill A11-CB25M Cung parameters End mill S4000/F1200/D0.1 XEBEC Brush S4000/F4000/1.0mm vs D0.2mm

3 02. Rotaon Speed vs. Feed Which has the greater impact on tool life? Decreasing rotation speed has the greatest impact on minimizing tool wear. Test condions Test piecealuminium Tools usedφ10 End mill A11-CB25M Parameter A Rotaon Speed(S) S4000 Feed(F) F4000 F/S1 Parameter B Rotaon Speed Feed : S2000 : F2000 F/S1 Number of Pass Wear amount 6 passes passes passes passes passes AVG/6passes Number of Pass Wear amount 6 passes passes passes passes passes AVG/6passes Tool wear: 1/3 2

03. How workpiece shapes impact brush life? Brush life depends on edge shape of a workpiece regardless of the same deburring parameter and traveling distance.

reference circle of gear and ring edge. Parameters S: 4000 D:0.5 F:2500 Number of Pass Gear external φ50mm Ring externalφ70mm Wear amount 1st 0.039 0.028 2nd 0.035 0.038 3rd 0.040 0.025 4th 0.045 0.

4 03. How workpiece shapes impact brush life? Brush life depends on edge shape of a workpiece regardless of the same deburring parameter and traveling distance. Test condions Test piecestainless steel JIS SUS304 ( DIN X10CrN:18-9) Tools useda31-cb25m, φ12 End mill Processing sequencegenerang burrs by end milling processbrushing Brush center is engaged on reference circle of gear and ring edge. Parameters S: 4000 D:0.5 F:2500 Number of Pass Gear external φ50mm Ring externalφ70mm Wear amount 1st nd rd th th Parameters S: 4000 D:0.5 F:2500 Φ50mm Gear traveling length =Φ50x3.14=157mm 0.04/157= = 0.25μm Approx. 2 mes faster tool wear AVG / φ / φ70 Φ70mm Ring traveling length=φ70x3.14=220mm 0.029/220= = 0.13μm 3

5 04. Are the inial parameters really right? Yes, initial parameter is right. Feed (from Initial parameter) Rim speed (Brush Dia 3.14 Rotation speed 1000) 9 When the value is 9 or smaller, deburring results are acceptable. Sengs [Inial Parameters from The Book (P7)] Rotaon speed : 80% of Max RPM = S4000 Feed: F2500~F4000 = F3000 Depth of cut = 1mm (Burrdirecon is horizontal) [Burr size] Up to 0.1mm root thickness [Brush / Material selecon] Test A : Red brush A11-CB25M / Aluminum Test B : Blue brush A31-CB25M / Stainless Steel Test A condions Test piecealuminium Tools useda11-cb25m, Face milling Cung parameterss1500 F900 D0.1 Test B condions Test piecesus Tools useda31-cb25m, Face milling Cung parameterss1000 F600 D0.05 A11-CB25M F4000 F3000 F2000 A31-CB25M F4000 F3000 F2000 S5000 S5000 F Rim Speed F Rim Speed S4000 S4000 F Rim Speed F Rim Speed S3000 S3000 F Rim Speed F Rim Speed =burr removed, =parally remained, = not removed =burr removed, =parally remained, = not removed

6 05. Does changing brush colors help to extend tool life? Blue brush shows 3 times longer brush life with the same deburring performance on aluminium workpiece. Changing brush colors with slower rotation speed helps to extend tool life. If surface roughness after brushing is allowed. TEST Material : Aluminium 5052 Test parameters below are adjusted to make the same edge condion. Edge aer face milling Red Brush Tool Rotaon speed (min -1 ) Feed (mm/min) Depth of Cut 12pass Tool wear Per pass Face mill Surface roughness Ra Rz White Brush Edge Break X: 0.243mm A Edge Break X: 0.243mm A21 A Seng red brush life as 1, the rao to other brush life are as below Blue Brush Edge Break X: 0.243mm 5 Red brush life: 1 White brush life: 1.17 Blue brush life: 3.41

06. Does changing brush size help to extend tool life?

It is recommended to use φ25 brush instead of φ6 or 15 brushes unless there are restrictions

Test Material : Aluminium 5052 Test parameters are adjusted to make the same edge condion as

Tool Rotaon speed (min -1 ) Feed Rate (mm/min) Depth of cut Wear 12pass Per 1pass Before

7 06. Does changing brush size help to extend tool life? φ25 shows about 5 times better cost-performance than φ15 in the same grinding performance. It is recommended to use φ25 brush instead of φ6 or 15 brushes unless there are restrictions of size or tool approach. Test Material : Aluminium 5052 Test parameters are adjusted to make the same edge condion as below. Tool Rotaon speed (min -1 ) Feed Rate (mm/min) Depth of cut Wear 12pass Per 1pass Before processing View from above Face milling Aer face milling A11-CB15M A11-CB15M A11-CB25M mes beer A11-CB25M Edge Break X: 0.287mm Edge Break X: 0.287mm 6 Seng φ15 brush life as 1, the rao to φ25 brush life is 4.8 t imes beer

axis direction tends to be less. Therefore, make the brush engagement less than 50% for equally rounded edge.

666 0.434 n=2 0.737 0.399 n=3 0.768 0.379 Av. 0.724 0.404 n=1 0.798 0.405 n=2 0.779 0.468 n=3 0.925 0.470 Av. 0.834 0.

8 07. How to produce R edge? (equally rounded in X axis and Z axis direcon) When brush contact area is less than 50%, grinding amount in X axis direction tends to be less. Therefore, make the brush engagement less than 50% for equally rounded edge. Changing the brush contacng rao 80% 50% 20% Before Brushing 80% X Z 50% X Z 20% X Z 20% of Brush Contact n= n= n= Av n= n= n= Av n= n= n= Av The greatest grinding amount Small X amount Test condions Workpiece: Aluminium 5052 XEBEC Brush: A31-CB25M ParametersS4000F2500D1.0

9 08. How can we make sharp-edge? 1 Positioning brush segment center on the edge makes sharp edge. Test condions Material: Aluminium 5052 Test piece: Tools used: A11-CB25M, φ10 End mill Burr generaon: Vercal direcon (*not applicable to horizontal burr) End-mail S:4000/F: 1200/D: 0.1 XEBEC Brush S:4000/F: 2500/D: Brush center (Normal) 2.Brush segment center Edge aer brushing Edge aer brushing Contact at the center of the brush segment to the edge 8

Face Milling View from above Test condions

1 ProcessMillingBrushing Millingfor sharp-edge

10 09. How can we make sharp-edge? 2 You can expect sharp edge by face milling the workpiece after brush process 1.Cung Process 2.XEBEC Brush 3.Face Milling View from above Test condions Test piecemc Nylon Tools useda31-cb25m, φ80 Face mill Cung parameterss1800f1080d0.1 ProcessMillingBrushing Millingfor sharp-edge This soluon is applicable to Aluminum workpiece also. Burrs generated. View from side Deburred but chamfered. No burrs with sharp edge. Edge shape aer 2nd milling X Z n= n= Burrs generated. Deburred but chamfered. No burrs with sharp edge. n= Av mm mm mm mm 9

11 10. How can burrs be prevented? When the edge angle is more than 150 degree, burr will not be generated. Mechanism of burr generaon Edge angle: 150 degree m 100m α 150 Cutting tool direction Edge angle: 60 degree Cutting tool Chip Work piece α Burr m 45 Burr This academic approach is studied by Mr. Kitajima of Kansai Univ. XEBEC has started DeburringUniversity with Prof. Kitajima. 200m After many repeats 100m 10 Source:Koichi Kitajima

12 11. How not to leave over lapping mark? A trochoidal pass does not leave over lapping mark on the workpiece. Standard Pass Surface condion aer standard pass with A11 brush Over lapping mark Ra(μm)0.3 Rz(μm)3.1 Original surface condion aer face milling Ra(μm)0.6 Rz(μm)3.7 Trochoidal Pass Surface condion aer trochoidal pass with A11 brush Ra(μm)0.1 Rz(μm)1.3 11

12. How to polish hard materials(hrc more than 57)? Rigidity brought by short brush projection length makes it possible to polish hard materials. Surface roughness Rz(μm) Graph 1 2.50 2.00 1.50 1.

13 12. How to polish hard materials(hrc more than 57)? Rigidity brought by short brush projection length makes it possible to polish hard materials. Surface roughness Rz(μm) Graph Surface roughness at each pass SKD61 SKD11 SKH51 Cemented carbide V50 Cemented carbide K10 Test condions Tool: A11-CB25M Brush length : 25mm Test Condions: S5000/F600/D0.2, Wet, Down Cut Before Polishing Aer Polishing Number of pass Characters are reflected Graph 2 Surface roughness at each pass (unit: Ra) Brush wear No. Material Hardness amount at start (μ/pass) 1 SKD61 HRC ~2 2 SKD11 HRC ~3 3 SKH51 HRC ~2 4 V50 HRA ~6 5 K10 HRA ~3 12

14 13. Does projecon influence tool life? Yes, the test result shows the tendency: Shorter brush projection will make the wear faster Test condions Test piece: Steel, S50C, 120X40X40mm Tools used: A31-CB25M, φ80 face milling cuer Rotaon Speed: 4000min-1, Feed: 2500mm/min, Depth of cut: 1.0mm, Wet processing Test data Number of Pass Average tool wear Accumlaon of tool wear Graph Tool wear Projecon offset at this point(55th pass) 摩耗量 Tool wear Number of pass Brush Exposure Long Short Long Short

Test condions Tools used A11-CB60M Brush Projecon: 15mm Rotaon Speed(min -1 ): S1000, S2000, S3000, S4000, S5000 The maximum rotaon speed is

15 14. What is the minimum depth of cut necessary? 0.2mm minimum of depth of cut is at least needed because bristles flair by 0.180mm when brush rotates with its maximum rotation speed. Test condions Tools used A11-CB60M Brush Projecon: 15mm Rotaon Speed(min -1 ): S1000, S2000, S3000, S4000, S5000 The maximum rotaon speed is S2000. Not in moon Rotang Flong Amount Rotaon Speed(min -1 ) Floang Amount S S S S S Graph The maximum RPM S1000 S2000 S3000 S4000 S

16 Please see homepage for details. < URL hp:// > Order XEBEC TECHNOLOGY CO.,LTD. Head office ADD , Koujimachi, Chiyoda-ku, Tokyo, , Japan TEL. +81-(0) FAX. +81-(0) URL hp:// XEBEC TECHNOLOGY CO., LTD. All rights reserved.

Deburring Technologies, LLC. Ceramic Fiber Deburring & Surface Finish Solutions.

Deburring Technologies, LLC. Ceramic Fiber Deburring & Surface Finish Solutions. Deburring Technologies, LLC Ceramic Fiber Deburring & Surface Finish Solutions www.deburringtechnologies.com 2015 Index Strengths of XEBEC Brushes 3 XEBEC Brush Surface deburring & finishing 4 XEBEC Brush