Automated burr analysis for troubleshooting manufacturing processes
A burr is a, usually unwanted, raised edge or a small piece of material remaining attached to a workpiece after a modification process.
Burrs are most commonly created by machining operations such as grinding, drilling, milling, engraving or turning. Burrs may be present in the form of a fine wire on the edge of a freshly sharpened tool or as a raised portion of a surface. Deburring accounts for a significant portion of manufacturing costs due to the need for additional operations, such as deburring and part cleaning.
Burrs effect on manufacturing processes
The deformed material at the edges of the machined workpiece significantly influences the properties of the workpiece. In other words, burr is a reason for machining errors and can even cause a premature, or a catastrophic failure of the unit during operation.
It complicates or prevents automated assembly. It causes damages to the workpieces during manufacturing and transportation. It disturbs the operation of electromechanical products. It is the cause of injuries among workers.
The burr forming during the machining process can also result in faster tool wear. In some cases, it makes the subsequent stages of the manufacturing process impossible.
Measuring burr for improved process control
Fast and comprehensive measurement of burr height helps in characterizing materials, controlling processes and process tools to prevent burr formation. This in turn minimizes manufacturing costs.
FocalSpec Edge Profilers are automated systems specifically designed for fast, non-destructive Burr Height (Picture 1), Rollover Depth (Picture 2) and Cut Edge Quality (Picture 3, 4) inspections. The parameters monitored are real-time burr height, Std, Ba, Bp, Bv and Bt.
Picture 1: Burr height profile
Picture 2: Rollover depth
Pictures 3 and 4: Cut edge quality
Edge Profilers EP250 and EP1350 utilize unique, optical line confocal imaging (LCI) technology. The system measurement principle is explained in the picture 5 below.
The scanning resolution (distance between the individual measurement lines) is user selectable up to 100µm. The system measurement accuracy is 1µm.
Picture 5: The measurement principle
The plug-and-play EP systems come as complete packages including all measurement, analysis and data storage tools needed. An easy-to-use calibration kit is included into the system delivery.