Product category:
Deburring, de-flashing and fettling
News Release from: Deburring Centre | Subject: Deburring calculators
Edited by the Manufacturingtalk Editorial
Team on 19 May 2008
Calculators check real costs and 'free'
deburring
Two free calculators can be used to check the 'real' costs incurred when an entire batch has been rejected because of 'a' burr, and if a 'free' deburring in cycle is actually 'free'.
The Deburring Centre, Poole, UK, has made available two free calculators that are designed to help in assessing the the 'real' costs incurred when an entire batch of machined parts has been rejected by a customer who has found 'a' burr, and the old idea of the 'free' deburring in cycle and what the actual cost is IApparently subcontractors said that more of their customers are rejecting entire batches of machined parts because they have found 'one' burr
This article was originally published on Manufacturingtalk on 1 Mar 2007 at 8.00am (UK)
Related stories
Machine tool users concern with deburring grows
In spite of the widespread use of CNC machine tools, some users are not machining out loose burrs, at best they are being made smaller, but customers expect zero burrs.
Thermal deburring is consistent, reliable
The thermal deburring process is non selective - 100% of potential loose burrs are removed and computerised controlled conditions mean that every process is consistent.
Extra costs are involved, namely transport, inspection, rework, more inspection, extra customer handling and loss of reputation.
It also results in having to more closely inspect any future work.
* Rework calculator - the rework calculator lists out all the incurred costs, obvious and hidden, and suggests that rework can be three times more expensive.
Further reading
Thermal deburring solves precision part problem
Considered to be almost impossible to deburr manually, a precision automotive component with two small holes drilled into a recess is being thermally deburred successfully.
Thermal deburring is cost-effective
Thermal deburring has been shown to be one of the most cost effective ways of internal burr removal, as it guarantees the 100% removal of all potentially loose burrs.
Thermal deburring specialist in universities
The Deburring Centre, the thermal deburring specialists, has formed links with universities and engineering students to raise the profile of the industry and explore better ways of deburring.
It shows the value of getting the work 'right-first-time'.
Maybe the machine shop has to go to a subcontract deburring specialist that uses dedicated machines to guarantee 'loose part free'.
Many machine shops are thinking of it as an insurance premium saving expensive extra work in the future, said the Deburring Centre.
It will also improve the machine shop's reputation replacing varaible manual deburring with automatic deburring.
* 'Free deburring' - the Deburring Centre said that its second calculator was based on a conversation with a manufacturer which claimed the usual 'done-for-free-on-the-machine' routine.
On closer examination, the deburring took 10.8s of machine time/component.
Certainly to subcontract out the deburring involved set-up and transport costs, which were a large part of the subcontracting deburring charge.
Subcontract deburring initially looked unattractive, but the Deburring Centre's calculator revealed a saving of around 20%.
The job ran regularly each week so saved over GBP 9,500/year.
Even better was that the calculator showed that by subcontracting out the deburring the user won back almost GBP 50,000 worth of extra machining capacity.
Essentially, the calculator showed that the machine shop was some GBP 60,000/year better off.
The simple Excel spreadsheet calculators take the user through a calculation step by step.
By entering a few figures, break even points can be found and savings can easily be justified to sub-contract out deburring to specialised companies, said the Deburring Centre.
The Deburring Centre told manufacturingtalk that whole point of the sub-contract market is that expensive machines, and dedicated operations can be performed by experts and produce better results, which are often far cheaper than in-house 'compromises'.
Very few places cast their own metals, said the Deburring Centre, and most would subcontract anodising or deep hole drilling.
Some companies even sub-contract sawing and/or machining.
So sub-contract deburring can make sense.
Especially when requirements stipulate the need to be free of machining burrs.
* Thermal deburring - the hydraulic industry has been benefitting from thermal deburring for almost 40 years, which by it's very nature, can guarantee every component to be 100% loose part free.
Because it uses a gas at up to 20 bar, no bore or gap is too fine and every burr is surrounded.
The 3,500 deg C heat wave that is generated causes thin burrs with large surfaces, that cannot lose the heat, to exceed their ignition temperature, and oxidise - whilst the surface of the component efficiently dissipates the heat throughout the mass of the component.
The Deburring Centre commented that it's often said that 'if it doesn't come off in the explosion it won't come off in service'.
That's why medical manufacturer Draeger Medical insists that a manifold unit in their rebreather is thermally deburred.
The Deburring Centre said that its two new calculators have resulted following the demand for the Centre's original deburring calculator.
That calculator compared in-house hand deburring to sub-contract automated machine deburring.
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