DESLAGGING - SLAGGRINDING

During plasma or gas cutting, strong melting often occurs, with the molten metal sagging on the beam-exit side.  In the plasma and flame cutting, the edge of the workpiece will produce slag and flash, and this can be quickly cleaned with very abrasive material or with even heavy slag removal hammers. This so-called slag occurs both on the inner and outer contours of the workpiece and must be removed for economical further processing.

Common manual methods for deslagging include chipping it away using a hammer and chisel, or grinding using an angle grinder. In terms of mechanical processes, excess accumulations of material can be removed by grinding with a soft contact roller. Another industrial method is knocking it off using a slag hammer brush made up of multiple flexibly mounted pins. 

PRE-GRINDING & DEBURRING

The burr can vary when punching, stamping, fine blanking or laser cutting your materials. Burrs created via laser cutting, fine blanking, stamping and punching adhere to the material in various strengths. Burr formation on laser-, plasma- and gas-cut, or stamped, sheet metal parts often cannot be avoided. Therefore finding a comprehensive deburring solution is crucial.  The burr respectively primary burr is a material formation on the cut edge of workpieces that protrudes beyond the original workpiece edges and surfaces.

Other deviations from the target state include, e.g., spatters on the workpiece surface caused by laser cutting, unevenness, or scaling of the surface. A by-product of removing primary burr is the so-called secondary burr. This spreads out in the direction of the workpiece surface and forms due to insufficient removal and simultaneous recasting of the residue material.

Primary burrs, spatters, unevenness and/or scale layers are normally removed by grinding. When removing primary burrs, the focus is on minimising the formation of a secondary burr. In order to remove these undesired secondary attributes from the sheet without leaving a residue, special support units are required for grinding belts, -discs or -sheets.

Deburring refers to the process of smoothing the rough edges of a metal object or component. To some, a part is considered deburred when its vertical burr is removed. To others, a part isn’t fully deburred until it has a radius on each edge.

DEBURRING & EDGE-ROUNDING - RADIUS

At this stage of the process, the primary and secondary burrs are removed and the edges rounded off. In order to lay the foundations for subsequent process steps (powder coating, wet painting, galvanisation, anodisation, bonding, etc.) and rule out any risk of injury due to sharp edges, the removal of the primary respectively secondary burr is often combined with the so-called edge-rounding. The edge rounding range from a few decimillimetres to radii of 2mm or even greater. These radii are now stipulated by standards such as e.g. DIN EN 1090.

The deburring and edge-rounding is carried out using flexible, abrasive tools with high adaptability to internal and external contours such as radii, boreholes and cut-outs. The corresponding deburring discs, deburring wheels, deburring blocks and deburring brushes are used on portable machines as well as grinding and deburring machines. The last mentioned machines have, for example, planetary head systems or oscillating units for uniform processing of the edges.

A good edge rounding result is characterized by removing the sharpness on the edges of your laser-cut or punched materials. This prevents injuries that may be caused by handling the material, while simultaneously improving downstream processing. Furthermore, a radius at the edge of the materials also improves paint adhesion.

Are you looking for the most beautiful and best rounding of metal?

A radius is created on the edge of the metal during edge rounding of metal products. This ensures that the sharpness of the edge is removed and it is given a uniform rounding. We offer perfection in edge rounding with a radius of up to two mm in a single pass. 

OXIDE REMOVAL

If you are cutting via a CO₂-laser or Fiber Laser with oxygen, we have the solution that removes any oxide layers along the cutting edge of the material.  Oxygen-cut workpieces have oxide layers on the cut edges. These „dark layers“ pose a risk for subsequent processes and can lead for example to chipping of the coating. For that reason they must be removed.

Mechanical removal of the oxide layer is achieved by grinding or brushing. Both processing options can be implemented for manual processing procedures. In terms of mechanical processing, it is mostly brushes that are used, which, thanks to a specially developed wire fill in an innovative multi-row arrangement, flexibly follow the contours of the workpiece and achieve blank metallic edge surfaces.

Profimach offers a wide range of deburring machines that also can remove your laser oxide. Our OEM factory developed in the beginning of 2015 a new brush Barrel to remove the laser oxide skin from laser-cut steel. This brush is to be used in the models with standard Rotary brush barrel machines (PRO Steel Versatile-Series) combining the excellent edge rounding and deburring results of the machine with the required oxide skin removal both from the interior as well as exterior contours ot the product.

If you have rusty surfaces, we have the solution that removes any oxide layers along the surface of the material. Steel, iron, aluminium, copper, magnesium,...

FINISH-GRINDING

Punched, fine blanking, stamped and laser-cut parts often require high demands on the surface. A beautiful surface is a pleasant side effect of the deburring process. In some cases, a specific type of surface finish could be necessary.

The purpose of this process step is to grind out scratch marks and create a decorative surface. Specific grinding patterns right up to a high-gloss mirror finish can be achieved on the sheet metal surfaces.

During the last processing step, it is primarily abrasive cloth, nonwoven abrasive, and felting tools that are used, as a continuous belt or roller. With manual processing techniques, the results, and their reproducibility, depend heavily on the operator. For mechanical finishing, the machine must have appropriate setting options.

Grinding with the express goal of removing material and decreasing material variation. This process removes the exterior oxide layer/skin and grinds the material much like a surface grinder – only using a wide belt abrasive.  We do reach surface flatness within 0.02mm on 1700 mm width.