Sanjeev Sharma

Professor, Deptt. of Mech. Engg.

CEC, Landran
Deburring
When a component is processed by a conventional
machining method, usually, it is left with burrs
specifically along the two intersecting surfaces. Such
burrs are undesirable from the view point of
performance of a component as well as safety of an
operator, or for that matter whosoever works with this
component .
Deburring
 Deburring is an important phase for manufacturing
quality products, especially in large scale industries.
 Attempts are made to reduce burr level by various
means, viz. by fixing speed, feed rates, and tool life, but
this could not be achieved for certain reasons.
 Hence, the quality of the products is affected. These
burrs have been successfully removed through
electrochemical means by a process called
electrochemical deburring
Deburring
Definition of Burr :-Burrs are three-dimensional in nature having
length (/), height (h) and thickness (t) as described in the following:

 l (Burr length) : length of the edge along the burr axis.

 h (Burr height) : distance of the burr projected above the

parental surface.

 t (Burr thickness) : thickness or width of the burr where it

joins the parental surface

 Burr Hardness : Hardness of the burr in the vicinity of

the base of the burr
Deburring

Terminology of burr
 Deburring
Classification of deburring processes:

 Mechanical deburring
 Abrasive deburring
 Chemical and Electro-chemical deburring
Thermal deburring
Deburring
Electrochemical deburring

 Generally employed for far away located as well as

inaccessible places where other deburring processes are
not effective.

 This process involves the use of flowing electrolyte for

conducting electric current for the electrochemical
reaction to take place.
ELECTROCHEMICAL DEBURRING (ECDe)
It consists of:

 Electrolyte system which provides high velocity to

the electrolyte flow.
 Electrical power system which supplies the
electrolyzing current.
 Mechanical structure which locates and provides
movement/mounting to the Electrodes.
 Separator which separates the sludge.
 Deburring
Principle of working

 When a voltage is applied between two metal electrodes immersed

in an electrolyte, current flows through the electrolyte from one
electrode to the other.
 Unlike the conduction of electric current in the metals in which
only the electrons move through the structure of the material,
'ions' (electrically charged groups of atoms) physically migrate
through the electrolyte.
 The transfer of electrons between the ions and electrodes
completes the electrical circuit and also brings about the
phenomenon of metal dissolution at the positive electrode or
anode (work piece).
 Metal detached atom by atom from the anode surface appears in
the main body of the electrolyte as positive ions, or as precipitated
semi-solid of the metal hydroxide, which is more common in
electrochemical deburring process.
Deburring
Deburring
Deburring
ECDe tool

 Usually insulated on all surfaces except a part which is

adjacent to the burrs.
 Instead of insulated tool, a bit type of tool can also be
used.
 The electrolyte is made to flow through inter electrode
gap.
 However, setting of dimensions of the bare part of the
tool, time of machining, and other machining
conditions are all decided by 'trial and error' method.
 The inter electrode gap (IEG) is usually kept in the
range of 0.1-0.3 mm.
 The deburring tool-tip should normally overlap with
the area to be worked by 1.5 to 2.0 mm.
Deburring
ECDe machine tool

 Multiple work stations

 Single power supply

 Electrolyte is recirculated after filtration

 For proper deburring→ burr characteristics should be

known
Applications
Biomedical, consumer appliances, aerospace,

automobile, etc
 Components → gears, splines, drilled holes, etc.

Higher reliability, reduced operation time & more

uniformity
Where burrs cannot be easily removed

manually
Applications
Applications

Examples of machine parts after deburring

(Courtesy AEG-Elotherm-Germany)
ELECTROCHEMICAL HONING
Honing is an abrasive machining process that
produces a precision surface on a metal workpiece
by scrubbing an abrasive stone against it along a
controlled path.
Honing is primarily used to improve the geometric
form of a surface, but may also improve the surface
texture.
Hone tool has a combined motion of rotation and
translation
The ECH process is five to eight times faster than
honing and four times faster than grinding.
It can provide surface finish up to 0.05μm.
It provides fine surface generation by honing and
fast material removal by ECM in a single operation.
The ECH process offers advantages of high metal
removal rate and extreme accuracy of 0.001mm in a
wide variety of hard to cut materials.
Other advantages include the ability to correct out
of roundness, cylindricity, circularity and axis
straightness in relatively round cylindrical work
pieces.
Advantages
Low tolerances.
Good surface finish is achieved.
Small Correction on workpieces is possible.
 Shaping and surface finishing is done in one
process.
Light stone/hone pressure is used in the process,
heat distortion is avoided.
Due to Electrochemical Dissolution phase, no stress
is accumulated and it automatically deburrs the part.
It can be used for hard and conductive material that
are susceptible to heat and distortion.
Disadvantages

Machinery cost is high.

Machining cost per piece increases as it is an addition

process.