Warum sind kryogene Entgratungsmedien die beste Entgratungsmethode?
20. September 2024
Deburring or deflashing is a vital part of the industrial manufacturing process, especially for precision parts. Whether it is injection molded plastic products, rubber parts, or metal castings, small burrs will inevitably appear during the production process, affecting the surface finish and precision of the final product. In recent years, cryogenic deburring technology has gradually become the first choice for various industries in terms of burr removal due to its advantages of high efficiency, precision and environmental protection. As one of the key factors of this process, the selection of cryogenic deflashing media are particularly important. This article will explore in detail why cryogenic deflashing media are the right choice and analyze its unique advantages by comparing it with traditional deburring methods.
Definition and working principle
Cryogenic deburring is a process that uses a low temperature environment to quickly cool and embrittle the burrs on the surface of the workpiece, and then accurately removes them through mechanical action. This method is particularly suitable for soft materials such as rubber and plastics. It can efficiently remove burrs without damaging the workpiece, and can also improve production efficiency and product quality.
The specific steps are divided into three main steps:
- Cooling: Put the workpiece into a low-temperature environment, usually using liquid nitrogen, and quickly cool the workpiece to -150℃, so that the burrs on the surface of the workpiece become brittle.
- Hardening burrs: Under low-temperature conditions, the burr part becomes fragile, while the main part of the workpiece remains relatively tough. Burrs are more fragile due to the different material properties of burrs and workpieces.
- Mechanical removal: Through mechanical vibration or slight physical impact, the brittle burrs are easily removed, and the surface of the workpiece remains smooth and intact.
Composition and characteristics
- Material composition（Click here to see product details）
The cryogenic deflashing medium is mainly made of polyamide 6 (nylon 6). The main shape is cylindrical or hexahedral, and there are a variety of colors to choose from, including translucent milky white, yellow, red and green. You can choose according to the color of the pre-treated workpiece, of which milky white and red are the most commonly used two. During operation, these different colors can facilitate operators to identify and manage in different application scenarios.
- Key physical properties
- Low temperature resistance
One of the remarkable properties of polyamide 6 is its high toughness at very low temperatures. Even at temperatures as low as -150°C, the material maintains a tough structure, ensuring that the deburring particles do not break due to low temperatures. This makes it an ideal cryogenic deflashing medium, especially when deburring soft materials (such as rubber and soft plastics), which can avoid damaging the main workpiece and effectively remove brittle burrs.
- High wear resistance
These nylon polyamide 6 media particles are carefully designed to have excellent wear resistance. After long-term use, they can still maintain their shape and effect, and have a long service life, which reduces the frequency of replacement and production costs. Plastic is light and more cost-effective in transportation, which is more economical in the long run.
- Lightweight and low hardness
Because it is a plastic medium, it is relatively light and has a low hardness, which means that even the surface of high-precision and sensitive parts will not be damaged during the deburring process. It ensures that the workpiece maintains its original smooth surface without creating new defects due to the impact of high-hardness particles.
- Color identification
Different colors of media can be distinguished according to their uses and applications, which is not only easy for operators to identify, but also allows for more efficient control of production processes.
- Chemical properties
- Chemical resistance
Polyamide 6 has good chemical resistance. Even in a highly chemically active environment, it is not easily corroded by substances such as acids and alkalis, which means that it can be used for a long time in various industrial environments without deteriorating due to contact with chemicals.
- Stability and non-toxicity
The cryogenic deflashing medium is made of non-toxic and harmless nylon material, which does not produce harmful gases or residues when used, and meets environmental protection requirements. This makes it not only safe for operators, but also has less impact on the environment, especially suitable for modern industry’s demand for sustainable production.
- High pressure resistance
During the deburring process, the contact pressure between the workpiece and the medium is large, but due to the material properties of nylon polyamide 6, it has good pressure resistance and will not deform or damage under high pressure, ensuring the continuity and stability of the deburring process.
Real shots of HLH products
The left side are milky white samples and the right side are yellow
- Economic benefits and long-term use costs
- Kosten-Wirksamkeit
Due to its wear-resistant, durable and recyclable characteristics, it can greatly reduce the cost of consumables in the production process. One-time investment can support long-term use, which is significantly cost-effective compared to traditional deburring media.
- Recycling and reuse
The material has good recycling performance. Through reasonable cleaning and reprocessing, these deburring particles can be reused, further reducing material consumption on the production line.
- Environmental protection
The product meets modern environmental protection standards and reduces the generation of harmful waste. Since its use process does not involve the application of chemicals, it has little impact on the environment and is very suitable for industries with strict environmental requirements.
Comparison with traditional deburring methods
Traditional deburring methods mainly include mechanical deburring, chemical deburring and thermal deburring. Each method has its advantages and disadvantages:
- Mechanical deburring relies on physical grinding, which is suitable for metal materials, but it is easy to damage the workpiece surface when processing soft materials.
- Chemical deburring uses chemical agents to dissolve burrs, which is suitable for mass production, but may cause pollution to the environment.
- Thermal deburring removes burrs by high temperature, but it has strict requirements on the material of the workpiece and is easy to affect the material structure.
These methods mainly rely on high forces and temperature changes, which may cause wear, deformation and even thermal damage to the workpiece surface. Mechanical methods often lack precision due to the need for manual or semi-automatic operation, and it is difficult to handle burrs with complex shapes or tiny structures. Although chemical deburring can remove some small burrs, it is easy to cause chemical residues, requires further surface treatment of the workpiece, and is harmful to some materials.
（We have written a more detailed article before, you can click here to read it.）
In contrast, the cryogenic deburring process has significant advantages in precision, non-destructiveness and efficiency.
- Precision and non-destructiveness
In a low temperature environment, burrs quickly become brittle, while the main material of the workpiece maintains its original toughness. This feature allows the cryogenic deburring process to remove burrs extremely accurately without damaging the workpiece surface. It is especially suitable for parts with high surface finish requirements, such as precision injection molded parts or aerospace parts.
- Hohe Effizienz
The cryogenic deburring process is suitable for automated equipment and can process a large number of workpieces in a shorter time, making the entire process faster and significantly improving production efficiency. In addition, due to the durability of low-temperature medium particles, the replacement frequency is reduced, further improving the continuity of production.
- Umweltschutz und Sicherheit
The process does not use harmful chemicals, avoiding the generation of chemical waste. Compared with traditional chemical or thermal deburring methods, cryogenic deflashing is environmentally friendly and safer for operators. In addition, the low-temperature environment can also suppress the generation of static electricity and sparks, reducing potential safety risks.
- Wide range of applicable materials
The cryogenic deflashing process is not only suitable for burring of plastic and rubber products, but also can effectively remove burrs on some soft metal parts. This wide applicability makes it an important tool in various industrial fields, especially in precision manufacturing and high-demand occasions.
Comparison with nylon polyamide deflashing media
Similarities:
- The main components of the two are the same, both are sandblasting particles made of polyamide 6 (nylon 6), and the shapes are also cylindrical or hexahedral, and the physical and chemical properties are basically the same.
- Both can adapt to low temperature environment and maintain good deburring effect at low temperature, especially suitable for processing rubber, injection molded parts and metal castings.
Although the composition and performance of the two are the same, the differences in their practical applications are mainly reflected in the following points:
- Applicable equipment
Cryogenic deflashing media are usually used in conjunction with liquid nitrogen cryo-finishing machine, while nylon polyamide deflashing media are more suitable for normal temperature deburring process, and the types of equipment used are different.
- Application scenario
Cryogenic deflashing media are more suitable for processing soft materials such as rubber products and plastics, and is particularly common in processing thermoplastics and thermosetting plastics, such as medical device components, precision rubber seals, etc. Nylon polyamide deflashing media are more suitable for removing burrs on the surface of metals and hard materials, such as stainless steel, aluminum alloy, copper, titanium, etc., and can also be used for surface treatment of some hard plastics.
- Operating temperature
Cryogenic deflashing media need to be carried out in an extremely low temperature environment, and the operation is more complicated, while nylon polyamide deflashing media do not require cooling equipment and is relatively simple to operate.
Application industry
- Luft- und Raumfahrt
- Background: The aerospace industry has extremely strict requirements on the precision of parts. Each part must meet extremely high-quality standards to work properly in harsh environments such as high temperature, high pressure, and strong vibration. Deburring parts such as aircraft engine components, aircraft shells, and transmission systems is a key step to ensure flight safety and increase the life of parts. Traditional deburring methods may cause minor damage to the surface of parts or material deformation, which is unacceptable to the aerospace industry.
- Effect: The cryogenic deburring process uses the cooling effect of liquid nitrogen to make the burrs on the surface of parts brittle and fall off quickly without affecting the geometric accuracy and structural strength of the parts. This method is particularly suitable for processing precision metal parts, composite materials, and high-strength alloys. It not only improves the surface finish of parts, but also significantly reduces the risk of damage to the microstructure. Through cryogenic deburring technology, aerospace manufacturers can more effectively control product quality and ensure its safety performance.
- Automobilbau
- Background: The automotive industry requires mass production of precision parts, especially in the manufacturing process of engines, seals, and electronic control systems, which have extremely high requirements for precision and functionality. For example, cylinders, seals and various transmission system parts in the engine must be smooth and flawless to avoid increased friction or reduced sealing. The internal and external parts of the car, such as lights, dashboards and plastic shells, also need to remove burrs and excess edges generated during the production process to maintain the beauty and precision of the product.
- Effect: The cryogenic deflashing process can quickly and accurately remove burrs from rubber seals and plastic parts, avoiding surface damage or damage to microstructures that may be caused by traditional methods. It can perfectly preserve the shape and function of the parts without affecting the overall quality of the parts. For example, rubber seals treated at low temperatures can ensure their sealing without damaging the surface due to the deburring process. In addition, the cryogenic deflashing process greatly improves production efficiency through automated equipment, which is particularly suitable for mass production needs in the automotive industry.
Rubber seals of different sizes
- 3D digital electronics and precision equipment
- Background: With the development of 3D printing technology, the manufacture of digital electronic equipment has put forward higher requirements for process accuracy. 3D printed parts usually leave fine burrs and excess edges during the manufacturing process. These subtle defects may affect the actual function and appearance of the parts. In the digital electronics industry, circuit boards, housings and other components also need to undergo precise deburring to ensure that they can work properly and extend their service life.
- Effect: For 3D printed parts, low temperature treatment can ensure that their complex geometric shapes are not destroyed while eliminating tiny surface defects. In the production process of electronic equipment, low temperature deburring can remove burrs on circuit boards and electronic components, avoiding circuit damage and functional failure that may be caused by traditional deburring methods. In addition, since the low temperature deburring process does not produce chemical residues or affect material properties, it is very suitable for the manufacture of precision equipment and electronic products.
Cryogenic deflashing media have injected strong impetus into the development of various industries with its precise, efficient and environmentally friendly characteristics. When the cold of liquid nitrogen embraces the workpiece, when nylon particles gently and firmly remove burrs, it seems like a perfect encounter between technology and art. It has witnessed the height of aerospace, the speed of automobiles, and the precision of electronics, and has become an indispensable partner of modern industry. In the days to come, may this magical medium continue to write a wonderful chapter in industrial manufacturing and create a more precise and beautiful world for us.
