Electrochemical Deburring Machine Guide

What is an Electrochemical Deburring Machine?

Electrochemical deburring machines are designed for removing small burrs from machined metal parts. Burrs refer to the imperfections, ridges, protrusions that are very commonly formed in machining processes such as grinding, milling, molding, stamping processes, and so on. For example, milling tools shave the metals while rotating, the irregular edges or burrs created unintentionally reduce the quality and smoothness of the metal parts.

The deburring tool in electrochemical deburring machines is the cathode (-) that is transferred by the electrolyte solution and precisely polishing, removing burrs by the anodic reaction on the metal workpiece. The reaction requires the presence of DC current and electrolyte solutions that are constantly supplied from the system. One point that must be aware of is the metal materials should be corrosion resistant due to the use of electrolyte solution. 

Compared to manual deburring or other deburring methods, electrochemical can consistently eliminate the burrs with microscopes without leaving visible or secondary burrs. The time the electrochemical deburring machine takes is half of the time of manual deburring, which makes it a must-have machine across industries to increase productivity and ensure the high quality of reliable metal products.

How Electrochemical Deburring Process Work?

In an electrochemical deburring machine, the electrolyte, which is the solution of salt or glycol, can convey the charge to the designed gap between the cathode (-) and metal parts (+). In the process, the electron will travel on the metal parts and remove the burrs and sharp edges. The designed distance between the pieces and the cathode is vital to regulate the deburring process. The fixed position of the deburring tool and the metal parts is key to determine the shape and the amount of material removal. Some electrochemical deburring machines also use probes with saltwater to perform electrochemical deburring more flexibly.

The electrochemical energy removes the burrs with high precision, leaving the challenging metal products intact. It is preferred to be used when burrs or sharp edges are difficult to reach. The speed of deburring or polishing is determined by the DC currents.

Construction of Electrochemical Deburring Machine

Electrochemical deburring machines consist of 3 essential parts, which include the plate and fixture, the electrolyte supplying system, the voltage controller, and some manufacturers also provide customized handheld probes.
Fixture: On the fixture plate, there is a design gap between the electrolyte solution and the part. The part needs to be clamped steadily and allow the electrolytic fluids to repeatedly slide into the gap.

● Electrolytic Fluid System: The system regulates the steady speed of saltwater, consistently providing electrolyte which acts under the DC current. It often is turned on or off by simply using the switch.

● Voltage Adjust System: The controller of DC current and electrolytic solutions might be housed in the same controller body for simple operation and adjustment. When the electrolytic fluid system is activated and the electrolyte is flowing, use the voltage adjust knob to regulate the voltage. The solutions will start bubbling, which indicates the deburring work is ready to begin. After a predetermined set time, the system will automatically shut the electrochemical deburring process off.

● Customized Handheld Probe: For lower-powered machines, operators can use interchangeable handheld probes to deburr and dip the holes and cross-hole intersections. The probes feature several 90 degrees cross holes that distribute the solution for deburring. With the development and customization of deburring probes and electrochemical energy, electrochemical deburring machines can reach every feature in manual deburring methods with higher accuracy.

Different Type of Burrs

Burrs are significantly common in several different stages of machining, such as stamping, grinding, milling, molding, drilling, casting, engraving, waterjet cutting, laser cutting. They are often inevitable. There are 3 main types of burrs: rollover burrs, Poisson burrs, and breakout burrs. Rollover burr is the most common one among three types. It is the small, curled metal bit on the surface of pieces. As for the Poisson burrs, they are formed in the case that metal accumulates at the end of the pieces. The Poisson burrs refer to the extending bits at the end. Last but not least, the breakout burrs are the protrusions that look like they are breaking out of the metal pieces.

Why Use an Electrochemical Deburring Machine?

The electrochemical deburring process can remove burrs at bore exits and holes in drilled holes, and for other imperfections difficult to handle when using conventional methods. It also solves the challenge of secondary burrs. High accuracy and high efficiency make electrochemical deburring machines not only ideal for deburring but several high precision applications. For example, the shaping of defined 3D surface profile, defined edge rounding, surface and sharp edge polishing, micro structuring

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