WHAT IS DEBURRING?

What is the deburring process?

Exploring Deburr Techniques, Deburring Challenges, and Solutions!

Imagine crafting external gears that mesh seamlessly, internal gears that turn smoothly, or gearboxes that power machines with precision. The secret sauce to this seamless operation? It's all about deburring, a crucial but often underestimated process.

When you dive into manufacturing parts like external gears, internal gears, pinions, pinion shafts, or gearboxes, you're essentially crafting the building blocks of functionality. Every imperfection, no matter how small, can impact the overall performance. That's where deburring steps in, ensuring that these components meet the highest standards of quality and reliability.

Detail of a metal burr. Metal burrs must be removed to ensure safety, functionality, quality control, and optimal performance of metal gears or components in engineering applications.

Understanding Deburring

What is deburring? Deburring is the method of removing unwanted burrs—tiny, often sharp, imperfections—from machined parts. These burrs can result from various manufacturing processes like CNC machining, plasma cutting, or casting. If left untreated, burrs can compromise part functionality, aesthetics, and safety.

Types of Deburring Techniques

Exploring Deburring Techniques and Challenges

1. Manual Deburring: This traditional method requires skilled operators using tools like scrapers, files, and brushes to remove burrs. While it allows for precision, it is labor-intensive and can be time-consuming, limiting its scalability for large production volumes.

2. Machine Deburring: Automated deburring machines offer consistent and efficient burr removal, making them indispensable in modern manufacturing. However, challenges such as complex part geometries and varied burr sizes require advanced technologies for optimal results.

3. Chemical Deburring: While effective for selective burr removal, chemical deburring demands careful handling of chemicals and disposal, requiring strict adherence to safety and environmental regulations.

4. Abrasive Deburring: Utilizing abrasive materials for mechanical burr removal can generate heat and friction, leading to potential surface damage or tool wear over time.

5. Electrochemical Deburring (ECM): Although precise, ECM setups can be costly to implement and maintain, requiring skilled technicians for operation and maintenance.

6. Thermal Deburring: While effective, thermal deburring methods like flame deburring may introduce heat-related distortions in parts, necessitating additional quality control measures.

7. Cryogenic Deburring: While innovative, cryogenic deburring requires specialized equipment and expertise in handling cryogenic fluids, adding complexity and cost to the process.

8. Ultrasonic Deburring: While capable of reaching intricate areas, ultrasonic deburring may struggle with harder materials or thicker burrs, requiring adjustments or supplementary processes.

9. Brush Deburring: While versatile, brush deburring methods may require frequent tool changes or maintenance, impacting production uptime and efficiency.

10. Waterjet Deburring: While precise and non-destructive, waterjet deburring may struggle with certain materials or intricate geometries, requiring careful process optimization.

The best machine deburring solution combines multi-axis capability with compliant technology. Unlike rigid robotic systems, multi-axis machines with compliant features offer greater flexibility to adapt to varying part geometries and burr locations. They can adjust tool angles and pressures dynamically, ensuring consistent and precise deburring across different parts. Additionally, machines with various tool options provide versatility, allowing for the use of different deburring methods depending on the part's specific requirements. This flexibility translates to improved productivity, reduced setup times, and enhanced overall quality in the deburring process.

Challenges in Deburring

Despite its importance, deburring poses several challenges:

1. Complex Part Geometries: Components like external gears, internal gears, and gearboxes often feature intricate geometries, making manual deburring impractical and time-consuming.

2. Burr Consistency: Burrs can vary in size, shape, and location, requiring tailored deburring solutions for optimal results.

3. Time and Cost: Manual deburring is labor-intensive and prone to inconsistencies, leading to increased production time and costs.

Automated Deburring Solutions

Automated deburring machines equipped with multi-axis compliant technology, like The MAX, offer unparalleled advantages over traditional deburring methods.

Here's a closer look at why they stand out:

1. Precision: Multi-axis compliant technology integrates CNC deburring tools into automated machines, ensuring precise burr removal even in complex part geometries like pinions and pinion shafts. This precision enhances part quality and functionality, meeting industry standards effectively.

2. Consistency: These machines deliver consistent results across batches, reducing rework and ensuring consistent part quality. This reliability is crucial for maintaining product integrity and customer satisfaction.

3. Efficiency: By automating the deburring process, manufacturers save time, reduce labor costs, and boost overall production efficiency. This efficiency improvement is key for meeting production targets and staying competitive in the market.

4. Flexibility: Multi-axis compliant technology allows for versatile tool movements, adapting to different part shapes and sizes seamlessly. This flexibility optimizes workflow and resource utilization, enhancing productivity and reducing downtime.

5. Quality Assurance: With precise control and monitoring capabilities, multi-axis compliant machines ensure stringent quality standards are consistently met. This quality assurance is vital for industries demanding precision and reliability, such as automotive, aerospace, and medical device manufacturing.

The integration of multi-axis compliant technology elevates deburring processes to new levels, offering unmatched precision, consistency, efficiency, flexibility, and quality assurance in modern manufacturing environments. These advantages make them indispensable tools for achieving superior results in part finishing and production optimization.

Choosing the Right Deburring Equipment

Do you need a Deburring Machine or a Chamfer Machine?

For understanding the key distinctions for automated gear finishing, click here.

When selecting deburring equipment, consider factors such as part complexity, production volume, and budget. Consult reputable deburring machine manufacturers like James Engineering, the deburr master known for their innovative deburring solutions tailored to various industries' needs. Top manufacturing companies go to the deburring experts for the best deburring machines.

Need a Chamfering Machine? Click Here

Burr Removal Methods

Exploring Deburring Tools and Techniques

When it comes to precision manufacturing, the right deburring tools and techniques are essential for achieving flawless finishes and optimal part functionality. Let's delve into the various deburring tools and their unique capabilities:

1. Deburring Brushes: Specialized brushes designed for deburring tasks effectively remove burrs from machined parts, ensuring smooth and precise edges crucial for product quality and performance.

2. Abrasive Wheels: Utilizing abrasive materials, such as grinding wheels or belts, abrasive deburring tools remove burrs and imperfections from metal surfaces, providing a consistent and uniform finish.

3. Chamfering Tools: Chamfering tools bevel edges, improving part aesthetics and reducing sharp edges, enhancing safety during handling and assembly processes.

4. Radius Forming Attachments: These attachments create precise radii on parts, essential for components like gearboxes and mechanical parts where rounded edges are critical for functionality and longevity.

5. Polishing Equipment: Polishing tools and materials, such as polishing brushes or compounds, achieve high-quality surface finishes, enhancing part appearance and meeting stringent industry standards.

6. Filing Tools: Filing tools are used to remove excess material and refine surfaces, maintaining precise dimensions and ensuring smooth edges for seamless part integration.

7. Washing Systems: Integrated washing systems clean parts thoroughly, removing debris, contaminants, and residual materials post-deburring, ensuring optimal cleanliness for subsequent processes or assembly.

In conclusion, understanding the deburring process, utilizing advanced deburring machines and tools, and choosing the right deburring method for your application are crucial steps in ensuring high-quality, precise machined parts.

By prioritizing deburring before chamfering, polishing, or other finishing processes, manufacturers can uphold the standards necessary for top-notch products in industries relying on precision components like automotive, aerospace, and machinery manufacturing.

If you are looking for the best deburring machines that have stood the test of time for their durability and used by top manufacturing companies across the world for chamfering and all purpose gear and part finishing.

Contact James Engineering at Sales@James-Engineering.com

Maximizing Efficiency: How Automated Deburring Systems Revolutionize Manufacturing

In the fast-paced world of modern manufacturing, the quest for efficiency is relentless. Every step in the production process must be optimized to meet the demands of precision, speed, and cost-effectiveness. One area where significant strides have been made is in the realm of deburring, and the introduction of automated deburring systems has revolutionized the manufacturing landscape. This article delves into the transformative impact of automated deburring, exploring its benefits, applications, and how it has become a cornerstone for maximizing efficiency in diverse industries.

The Evolution of Deburring:

Deburring, once a manual and time-consuming process, has undergone a remarkable evolution with the integration of automation. Traditionally, workers meticulously removed burrs and sharp edges from machined components, a task that was not only labor-intensive but also prone to variations in quality. Automated deburring systems have emerged as a game-changer, offering a streamlined and consistent approach to this crucial manufacturing step.

Benefits of Automated Deburring Systems:

Precision and Consistency:

Automated deburring systems provide unparalleled precision, ensuring that every component is treated with the same level of accuracy. This consistency is vital in industries where even the slightest deviation from specifications can lead to performance issues or product defects.

Time Efficiency:

Time is of the essence in manufacturing, and automated deburring significantly reduces cycle times. The swift and continuous operation of robotic systems allows for a faster throughput of components, contributing to overall production efficiency.

Labor Cost Savings:

The automation of deburring processes translates into reduced labor costs. Manufacturers can reallocate human resources to more intricate tasks, while automated systems handle the repetitive and time-intensive nature of deburring.

Enhanced Safety:

Manual deburring poses risks to workers due to sharp edges and repetitive motion injuries. Automated systems eliminate these safety concerns, creating a safer working environment and reducing the likelihood of workplace accidents.

Applications Across Industries:

Automated deburring systems find applications in a myriad of industries, from aerospace and automotive to electronics and medical device manufacturing. The versatility of these systems allows them to adapt to various materials, geometries, and part sizes, making them an invaluable asset in diverse production environments.

Technological Advancements:

The 11-Axis MAX system has further enhanced the capabilities of automated deburring systems, taking them next level. Intelligent and easy to use, these systems adapt to different materials and geometries, optimizing the deburring process for each unique component.

Case Studies:

Several manufacturing leaders have reported substantial improvements in efficiency, quality, and cost savings after implementing automated deburring systems. Real-world examples showcase how these systems have become a cornerstone of lean manufacturing practices, driving competitiveness in the global market.

The integration of automated deburring systems represents a transformative leap forward in manufacturing efficiency. As industries continue to push the boundaries of innovation, automated deburring emerges as a key player, ensuring that components meet stringent quality standards while optimizing production processes. Manufacturers embracing these advanced systems are not just keeping pace with the demands of the market; they are setting new standards for efficiency and reliability in the modern era of manufacturing.

To learn more about what all the MAX has to offer, email us or call us at (303) 444-6787

Mastering Precision: A Comprehensive Guide to Overcoming Part Finishing Challenges

In the intricate realm of manufacturing, achieving precision in part finishing is an ongoing pursuit that directly influences the quality and functionality of the final product. This comprehensive guide explores the common challenges encountered in part finishing and offers valuable insights into overcoming these hurdles with the help of advanced deburring and chamfering machines. Let's embark on a journey to master precision in part finishing.

1. Unwanted Burrs and Sharp Edges

Challenge:

Unwanted burrs and sharp edges can compromise functionality and aesthetics.

Solution: Unwanted burrs and sharp edges can be effectively removed through various methods. Manual tools like files, abrasive brushes, and rotary deburring tools offer precision, while techniques such as abrasive blasting, chemical deburring, and thermal methods provide automated solutions. Advanced approaches like electrochemical deburring, cryogenic methods, waterjet cutting, and laser deburring cater to specific needs, emphasizing the importance of selecting the most suitable method based on material, part complexity, and production requirements.

Additional Insights:

Advanced deburring machines, like The MAX, employ precision techniques to eliminate burrs without compromising structural integrity.

Variability in Burr Types: The MAX adapts to various burr profiles.

Critical Edge Preservation: Ensures meticulous burr removal while preserving critical edges.

2. Inconsistent Surface Finish:

Challenge:

Achieving a consistent surface finish is crucial for quality standards.

Solution: Achieving a consistent surface finish is crucial for quality standards because it directly impacts the appearance, functionality, and performance of a finished product. Consistency ensures uniformity in texture and appearance, which is especially important in industries where aesthetics matter, such as automotive, aerospace, or consumer electronics. Additionally, a consistent surface finish is indicative of precision and attention to detail in manufacturing processes, reflecting a higher level of quality and meeting the stringent standards expected by customers and industry regulations. In applications where friction, wear, or corrosion resistance are critical factors, a uniform surface finish is essential for optimal performance and longevity of the final product. Overall, consistency in surface finish contributes to the reliability, durability, and overall quality of the manufactured components or products.

Additional Insights:

Multi-axis deburring and chamfering machines, like the 11-Axis MAX provide control for a uniform finish, meeting specifications.

Large Batch Consistency: Guarantees uniformity even in high-volume production.

As well as the flexibility to run one off pieces.

3. Material Compatibility:

Challenge:

Diverse materials require tailored approaches for consistency.

Solution: Versatile machines handle various materials, ensuring adaptability and consistent finishing.

additional insights

Material-Specific Challenges: The MAX addresses material-specific intricacies.

Transitioning Between Materials: Seamless adaptation minimizes downtime during material shifts.

4. Complex Geometries:

Challenge

Achieving uniform finishing in intricate geometries is challenging.

Solution: Advanced machines with multi-axis capabilities navigate complex shapes with precision.

additional insights

Features: The MAX’s 11-AXIS accesses intricate internal spaces efficiently unlike anything on the market.

Variable Thickness Challenges: Precision extends to variable thicknesses, overcoming challenges associated with varying thicknesses within a single part.

No Masking: Our patented Focused Deburring saves time with precision, never mask another part.

5. Efficiency and Speed:

Challenge

Meeting tight deadlines while maintaining high precision is a common struggle.

Solution: High-speed deburring machines with multi-axis control significantly reduce processing times without compromising quality.

additional insights

Rapid Job Setup: The MAX streamlines job setup processes for increased efficiency, by employing quick set up and part change out.

Adaptability to Production Changes: Flexibility allows quick adjustments to production changes. Chamfer, polish or deburr a one-off part or 1000’s of the same part. Adaptability allows various size manufactures to employ automation.

Conclusion:

In the complex landscape of part finishing, mastering precision requires overcoming various challenges. Advanced deburring and chamfering machines, exemplified by The MAX, offer practical solutions to elevate your manufacturing process. By integrating these technologies, you can navigate the intricacies of part finishing with confidence, achieving not only precision but also efficiency and sustainability. Explore the transformative potential of advanced machinery and stay ahead in the pursuit of mastering precision in manufacturing.

 Contact us for more information on 11-axis machining. Sales@James-Engineering.com

The Machine Shop at James Engineering

The Colorado-based OEM shop is known for their one-of-a-kind deburring and chamfering machines, but they also have a precision-focused machine shop that’s willing to take on any project that comes their way. If you’re in the market for a low to medium volume machine shop who guarantees quality products, reach out to James Engineering today at (303) 444-6787.

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What is our shop capable of?

Dave: We have 3 mills and 2 lathes. One of the mills has 4th axis capability. We’re capable of holding concentricity within 5/10ths in most cases without have to do any crazy set ups. We can do round parts, square parts, just about any shape part that you want.

Scott: We’ve got a live tool lathe with a bar feed option and multiple seats of programming software. We’ve got that 4th axis mill, another smaller mill with a 20-inch bed, and we’ve got a 60-inch bed large mill.

How many parts a week do we typically make?

Dave: That’s pretty subjective because we do short run production, so most of our time isn’t spent making parts, it’s getting ready to make a part and getting a part set up to run. Typically, we could spend half hour programming, half our setting up, and basically we could run for 15 minutes and then be done (in some cases). We can’t really quantify the quantity of parts per week because we’re more set up to be a tooling or prototype shop versus a production shop.

Can customers send in their own designs?

Dave: We quote on stuff and have stuff made for outside companies. We have engineering services, so people can send in a concept and we could do the whole thing, or they could send in a thing that’s basically done and we could create drawings for them, things like that. We have start-to-finish capability, or we can pick up a project that they’re already halfway through. We can also provide good drawings, give them a model.

What are some basic jobs we do frequently?

Dave: We do a lot of gun parts, automotive stuff, motorcycle parts. It really is just a gamble. Basically, anybody who walks into the door with a project, we can take a look at it and see if it fits our capabilities fairly easy and we’ll do it. We’ve done a lot of welding jobs lately, too. We’ve done a lot of stuff for RoboCon; we’ve made a lot of platforms and fixturing.  We’ve made brownie bowls, and stuff for volleyball companies, it doesn’t really matter what industry comes in.

Scott: So we’ve got a lot of high end, high precision parts that we make. For example, we’re making a mount for a vehicle right now. Our perfect job is a volume job. We’re really looking for anything from prototype to a few thousand parts a week. I wouldn’t call ourselves high volume where we’re tens of thousands of parts per week, but we’re definitely looking for that low to medium volume area.

What makes our shop stand out?

Dave: Our attention to detail and the quality of our parts. That’s something that we take a lot of pride in. We try to go that one step above, whether it’s by deburring or not putting a scratch on it by pushing it across surfaces, things like that. We take really good care of all the parts we make, and it’s a lot easier to go in and get the quality you’re looking for when you’re not making thousands and thousands of parts.

Why is it significant for our machine side of business that we make our own parts in-house?

Dave: We can control our own quality because our standards are really high. To be able to get the tolerances and stuff we need we can hardly get other people to make them for us. We put a dimension on a drawing and expect you to hold it, so in some cases we put really tight tolerances on things with reason, and when other companies see those tight tolerances the cost goes up automatically (whether it’s justifiable or not). It’s more cost efficient for us to do it.

Scott: We have to make all of these parts here in-house because we really can’t afford to job much of this out. We’ve got to keep our profit margins where they need to be. We have to hold pretty precision fits because we’ve got a 3.2 million resolution encoder here turning all of these [parts] on this five-axis manipulator.

How do your own deburring machines fit into the machine shop process?

Scott: When we make these parts, we do a lot of in-machine deburring. We’ll go through and we’ll machine this edge with a chamfer tool. But the problem is, when we machine the edge with the chamfer tool, the chamfer tool creates two sharp edges. We still have this problem where a technician has to go in with Scotch-Brite and deburr this. So we don’t want that abrasive to get into our CNC machine, because if that abrasive gets into our machines, it gets down into ways and slides and it wears the machine out. That’s where the market is for our deburring machine.

The Difference Between Grinding, Polishing, and Deburring

Grinding, polishing, and deburring—anybody who knows anything about the precision machining process knows that these three processes are a.) crucial, and b.) acts of surface finishing. These three processes are very similar to each other, and for decades have been making people ask the same questions: What’s the difference? And why do we need to do all three processes? Both of these questions are valid, and we have the answers to both below.

The difference between grinding, polishing, and deburring.

1. Grinding

This is the process of removing material and shaping a workpiece into its final form. Grinding can be done on a multitude of materials, such as plastic, ceramic, and many different metals (stainless steel, titanium, high-nickel alloys, etc.). In order to complete this process, grinding wheels of different abrasives are used in various machines made specifically for grinding. It’s important that the correct kind of abrasive is used, as too soft of an abrasive can’t grind a workpiece enough, while too hard of an abrasive will damage a workpiece and result in decreased part quality or scrapped part. Overall, grinding is essential because it improves a part’s surface finish, which not only provides the aesthetic many industries require, but also ensures the removal of pesky surface imperfections.

2. Polishing

Polishing is the process surface finishing, which is also known as the process of improving surface quality. Using softer, smaller abrasives like polishing compounds and wheels, surface imperfections such as scratches and unwanted film/layers are removed to achieve a part’s desired texture (as different industries require different surface finishes). Polishing can be done by hand, machine, or robot, as it doesn’t require quite as much precision as grinding or deburring do. This step can be taken farther with buffing, which gives parts a finish similar to that of a mirror.

3. Deburring

This process is the act of removing burrs from a part’s surface. Burrs are extra bits of metal that form as a part is being cut, and can be extremely harmful both for a part’s functionality and the overall assembly it’s a part of. Deburring can be done by hand or in a machine, though hand deburring proves to be inconsistent and costly. The process of deburring requires extreme precision, as any leftover bit of metal can cause inconsistencies that result in the decrease of a part’s longevity and efficiency. Deburring is required for any part that has been previously machined and can be done on a variety of different materials, such as ceramic, stainless steel, wood, titanium, and more. What makes it an essential process is it ensures parts meet industry standards and helps reduce the possible formation of stress risers.

Surface Profiling

Seeing as all three of these processes fall under surface finishing, it’s important to know how surface finish is measured. Surface profiling is the measurement of a surface’s roughness, which allows manufacturers to know how adequately prepared a part is for further processing, especially when it comes to the part coating and assembly stages. A profilometer is the tool used to measure these surfaces and can be split into two categories: contact and non-contact. Contact profilometers use a stylus to map out the highs and lows of the surface (also known as peaks and valleys) which allow operators to gauge how smooth or rough a workpiece surface truly is. A non-contact profilometer uses image sensors to detect a surface’s texture. While this is the faster of the two profilometers, it’s extremely sensitive to any dirt or oil that may be coating a part’s surface.

Why does manufacturing require all three processes?

Ultimately, grinding, polishing, and deburring are all needed for the same reasons: dimensional accuracy, part efficiency, corrosion resistance, and improved functionality. All of these processes refine parts so they’re safe, functional, and meet industry standards. In other words, it’s the manufacturing equivalent of editing a piece of writing before publishing. A part might work fine enough after it’s just been cut, but without grinding, polishing, and deburring, it probably won’t fit into its assembly correctly, and it certainly won’t reach its ultimate level of efficiency and precision. The time and energy spent on these three process ensure that overall assemblies will require less maintenance, which saves operators and businesses precious time and money.

The Machine that can do it all

One of the most efficient ways of grinding, polishing, and deburring on the market is by using the MAX, an all-encompassing finishing machine sold and manufactured by James Engineering. This deburring and chamfering machine is capable of carrying out all three process concurrently. This means a part can be deburred, ground, and polished in one go. This machine also has a consistent precision unreachable by any hand-done method or other machine. The MAX makes all three processes easy and affordable, which ultimately revolutionizes any operation.

To watch the MAX in action, check out the James Engineering YouTube channel here.

To inquire more about the MAX, call (303) 444-6787 today.

What Is Gear Chamfering?

Simply put, the process of chamfering is cutting a 90-degree edge at a 45-degree angle as a way to remove stress-rising sharp edges, as well as allow for smoother assembly. That makes chamfering sound easy, when in reality it’s actually very time consuming, no matter the method of approach.

Gear Chamfering can truly be broken down into four separate surface-finishing processes: deburring, chamfering, radiusing, and radius-chamfering.

-       Deburring is the process of grinding off burrs, which are bits of excess metal created in the metal cutting process. Burrs are extremely problematic and will cause issues in assembly as well as overall part efficiency. Assuming the deburring has been done properly, all burrs will have been completely removed, leaving nothing but a sharp edge.

-       Chamfering, as stated above, is the process of cutting that sharp edge at a 45-degree angle (which is the most common angle, but not the only one they’re limited to). Chamfering can be done with a myriad of tools, such as brushes, sandpaper, grinding wheels, and Scotch-Brite. However, in the process of shaving down this one sharp edge, two more are created on either side of the original, and if the tool being used is worn down, burrs can be created as well.

-       Radiusing is the process of completely rounding out edges until it’s completely smooth. While chamfering is smoother than just leaving a part deburred, it still is cut at a noticeable angle that can be seen and felt. Radiusing feels and looks rounded (just like how a ball is round without any hard edge), and can also be carried out via brushes, grinding wheels, and sandpaper. It’s crucial to know what materials these tools are made out of, because the materials will affect the quality of the radius; if a material is too abrasive, it will be impossible to reach a true radius. A true radius is when the edges of a 90-degree angle go tangent to tangent without any surface imperfection.

-       Radius-chamfering is when a part receives both radiusing and chamfering. The sharp angle is cut at the usual 45-degree angle, and when those two extra sharp angles are created, they are radiused to create smooth transitions between chamfers.

When it comes to how chamfering is done, there’s a few methods operators can choose from—machine-based, hand-based, or robot-based.

Different types of gear chamfering machines are capable of different sub-categories of chamfering. For example, a CNC machine can decently deburr a part, a lathe can adequately radius-chamfer a part, and a mill can chamfer a part. All of these options are valid, but not a single one of them can chamfer, deburr, and radius a part; separate machines are needed. Not only that, but these kinds of machines require in-depth programming for every single part in order to be exact. The MAX by James Engineering is capable of carrying out all four chamfering processes with heightened precision, as well as little programming.

Doing any of these processes by hand is technically achievable, but it ultimately proves to be more troublesome than it’s worth. Manufacturing is an industry that requires precision, as things will fall apart and fail to work correctly without it, and doing these processes by hand simply does not provide adequate enough precision. Even the best operator can slip or tremble, and man cannot repeatably guarantee a consistent chamfer. Hand chamfering is acceptable in a pinch, especially if only one or a handful of parts require it. But for higher volume operations, not only does hand chamfering not produce consistent results, it also is extremely time and cost inefficient. Scrap rates are the highest with hand chamfering, and the time it takes operators to complete one part is what it would take a CNC to do two or three, or the MAX to do a hundred.

Robots are only slightly better at gear chamfering than when done by hand. While they do have better mobility than most machines, they lack precision. Robots are perfect for operations that require the moving and placing of items, but they just cannot match a machine’s precision. Robots also require a lot of laborious programming, overall making them a poor method of chamfering.

Out of all these methods, the MAX is hands down the most reliable and efficient. As an all-encompassing finishing system, it is capable of deburring, chamfering, radiusing, and radius-chamfering any part or gear, no matter its complexity. It does require some initial programming, but once a part/gear has been loaded in, the MAX will remember it for future use, meaning operators no longer have to manually input adjustments themselves (James Engineering calls these programs “recipes”). The MAX is also capable of repeatable precision down to the fifth decimal. For reference, the average human hair measures to .003 inches. The MAX can repeatably work down to .00001 inches, and even beyond that.

Precision in chamfering is key, because the less precise a chamfer is, it’s more likely that stress risers will appear with continual usage. Stress risers are tiny cracks that form at a part/gear’s weakest point of contact (like the tooth on a gear). If a part is not adequately deburred or chamfered, what will happen is those sharp edges will slowly break off until a part or gear’s structure is ultimately compromised. So that previously mentioned tooth could fall off, for instance. That is extremely dangerous, both for the assembly itself and the people operating it. For example, a helicopter would crash if one of the gears in its motor failed. When it comes to chamfering, the higher the precision, the better. The precision achieved by the MAX means that parts/gears processed through it are extremely unlikely to form stress risers even after years of use.

There’s a misconception about chamfering that it’s done easily. Even with an advanced machine such as the MAX, chamfering is no “easy” feat. If a chamfering operation appears to be “easy”, it’s probably being done sloppily and inefficiently—and precision takes time and effort.

Knowing the correct way to chamfer is a gamechanger with any operation, as well as being able to recognize when a chamfer is done correctly. If it is, parts will fit together with no resistance and work efficiently for the entirety of their lifetime. And when parts work correctly, overall assemblies will perform at their best.

To visibly see how chamfering is done, watch a short video clip here.
To contact James Engineering about the MAX’s chamfering abilities, call at (303) 444-6787

Deburring Debunked: The Ultimate Challenges

The process of finishing parts and gears before assembly comes with a set of its own unique issues. This manufacturing process is vital and cannot be skipped, or else assemblies would fail due to poorly prepared parts/gears. Finding simple, efficient solutions to these issues is crucial, as it ensures overall effectiveness and quality of an assembly.

We interviewed Jim Richards, the founder of James Engineering, and asked him what he finds to be the top three part finishing challenges. Richards has been at the forefront of the deburring industry for a little over forty years and is seasoned when it comes to overcoming a challenge.

1. Conflict with Customer Prints

“One of the biggest challenges is meeting customer requirements within blueprints,” Richards says. “Sometimes, the people writing these specifications don’t understand the tooling that is required with deburring or how it works.” Richards later goes on to say that this particular issue is not only the hardest one to solve, but the most common one faced within the deburring industry. The process of deburring is very complex, and if blueprints aren’t drawn correctly, deburring can seem impossible on that specific part because of the ultimate limitations that come with the process. “Sometimes we don’t have the kind of tools to do what the blueprints ask of us,” explains Richards, “but we’ve learned to solve these problems over the years.”

What Richards has learned is that collaboration and adaptability are key when it comes to sidestepping this conflict. The engineers at James Engineering are in constant contact with their customers in order to meet their requirements in achievable ways. “Sometimes we get companies who send in drawings that we absolutely cannot change,” Richards adds, “Take Pratt & Whitney for example. That’s a big company that requires consistency, we can’t just up and change what they’ve sent us. So we have to do what they’re wanting us to do. But we’ve learned to do the job.”

2. Cost of Consumables

“Understandably, you can’t build a quality part with cheap materials,” Richards starts, “Sometimes you have to spend a little more to get a better part.” Richards explains that every James Engineering machine is built with the intention of using particular brands or items. If these specifications aren’t followed, the final quality cannot match what is promised by one of their machines. “The quality of chamfer we need and produce is from running a finer grit grinding wheel,” Richards explains when asked for an example. “The wheels we use are made of cotton, which don’t last as long as these tiger claw, aluminum oxide coarse wheels. Well, these coarse wheels remove metal fairly easily, but they leave a really jagged finish. People run these wheels for economic reasons, because yes, they’re cheaper, but they will destroy a part.”

James Engineering machines are known for producing beautifully precise and consistent chamfers. This is greatly due to the kind of grinding wheels they use, which are comprised of cotton and resin. The idea of using cotton in a grinding wheel is surprising to many, but in terms of chamfering, this kind of wheel is a champion of it. The cotton acts as a dampener, meaning these wheels’ tendency to bounce is extremely low, especially compared to woven fiberglass wheels. While the cost of running these coarse fiberglass wheels is smaller up front, it will actually cost a greater amount in the long run due to a high rate of scrapped parts. This is a great example as to why using the intended tools is extremely important for overall production. “We have to establish what we’re going to use and that has to be followed.”

 3. Consistency of Parts Presented

The third most frequent challenge Richards has seen is the consistency of parts presented. “We often get sample parts from customers, and their conditions will sometimes change. So then we have to take samples of burrs and look at their size and decide what we can and cannot do. I’ve seen samples come in with burrs an inch and a half tall!” Essentially, machines are manufactured to handle a consistent, established size of burrs for specific parts. For example, a company will send in a dozen samples of the same part. Eleven out of twelve of these parts have burrs roughly the same size, but the twelfth will have a burr substantially larger than the rest. This twelfth part wouldn’t receive complete deburring using the same specs as the other eleven parts—it would require an entirely different set of measurements, tooling, and time. But this issue is easily avoidable as long as customers take care of one particular aspect: changing the part cutter on their CNC machines.

“When you’re making a gear or part, the hob cutter will start off as razor sharp, but it eventually wears out, naturally. We [at James Engineering] have to make sure we qualify when you change your cutter. Operators can’t be running their cutters down to total wear then give us huge burrs. So we need to establish the point of which they change their cutter so we receive parts that we’re capable of deburring.”

This may sound laborious and costly, but again, this ultimately saves money in the long run. If cutters are changed regularly, the predictability and consistency of their parts becomes manageable. This then makes it easier for James Engineering to manufacture machines that work perfectly for a shop’s needs. If the cutter is not changed frequently, extra tools must be added to a shop’s machine, costing them more in money and processing time. “You’re better off to change the cutter and leave our process simpler,” Richards explains.

So, how avoidable are these challenges?

“These are all very easily avoidable!” says Richards. “With consistency of parts presented, we just need to qualify the part that we’re going to deburr and establish that in writing. With the cost of consumables, we have to establish exactly what we’re using and write it into the warranty. Conflict with customer prints is always trickier, as we sometimes can’t change anything about the blueprints we’re sent. [We just] have to be adaptable.”

James Engineering prides itself on being a thorough and precise business—these values can be found at the core of the company. They are what make their machines so consistent and products so repeatable. There’s a reason why their deburring systems are at the top of the market.

What are the ultimate solutions?

With each customer comes a new challenge, but conflict with customer prints, the cost of consumables, and consistency of parts presented are usually given. However, after decades of dealing with the same issues, Richards and those at James Engineering have found that the following are the top solutions:

·      Adaptability

·      Reliability

·      Flexibility

·      Thoroughness

·      Consistency

·      Communication

By adhering to these six simple values, no challenge is too much for James Engineering. 

To learn more about their machines, click here.

To send any sales inquiries or further questions, email Sales@James-Engineering.com

Types of Deburring

Punch Deburring

Since its perfection in 1770, sheet metal has become a commonly used material within the manufacturing world. One of the most popular ways of cutting and manipulating sheet metal is a method called “punching”. A punch machine uses interchangeable tools to cut out shapes from the sheet metal, and it’s vital that these tools are sharp. If they aren’t, they require more force to cut through the metal, which can lead to the formation of burrs. Punch machines can deburr the pieces of sheet metal they just cut, and they do so with another set of interchangeable tools, which are meant for deburring. This method of deburring works well for pieces cut from sheet metal, but it’s extremely limited when it comes to parts with complex geometries.

Tumbling Deburring

This method involves parts/gears being tumbled in a barrel full of water and loose materials (known as tumbling media), such as glass beads, steel, or plastic. The force of the material and parts tumbling against each other will break off any present burrs and smooth out a part’s surface. Operators must be able to choose their media correctly, as some will do extreme damage to gears/parts made of other certain materials. For instance, steel parts must be paired with steel material. Tumbling is a good option for larger parts/gears, as it is a quicker way to remove their burrs compared to doing it by hand, and they are less likely to suffer overall structural damage from it. However, that risk is still there, and it can ultimately do more harm than good.

Vibratory Deburring

Vibratory deburring is like the tumbling method in the sense that parts are put into a barrel with tumbling media, but it’s more effective and gentler than its cousin method. When the loose material is vibrated against parts/gears, the force shears off burrs and other imperfections with equal force, making it a safe method for smaller, more delicate parts. This process is used frequently within industries such as the aerospace or medical industries and can even be used for parts made of wood or plastic.

Cryogenic Deburring

The cryogenic deburring method is similar to freezing off a wart. Parts are put into low-temperature chambers, where burrs are then frozen until brittle. The burrs will then get knocked off part surfaces when non-abrasive media is thrown into the chamber. This process doesn’t leave residue and preserves the surfaces of parts of any size. It’s a good option for processing large amounts of parts/gears at once, but it still lacks the precision that is necessary for complex parts.

Hand Deburring

This might be the most common—and the most time consuming—deburring method out there. Workers use handheld tools to manually complete processes such as brushing, edging, chamfering, polishing, and of course deburring. While this method allows for focused precision, workers are limited to working on one part at a time, making it extremely inefficient for high or medium volume shops. These workers also require adequate training and experience, seeing as one mistake can scrap an entire part; a little too much material taken off a part/gear can cause it to not fit into its greater assembly properly and affect its long-term efficiency. Another issue with hand deburring is that consistent chamfers are hard to achieve with it, and chamfers of poor quality will also affect the function of a larger assembly. Some manufacturers still prefer hand deburring to other methods, but it costs too much time and money to be used widely.

Electrochemical Deburring

Electrochemical deburring is a unique method of deburring that shoots currents of voltage between a cathode and a burr, ultimately dissolving said burr. This process can remove any sort of excess unwanted surface material. It’s important to maintain a gap between the cathode and part needing deburring, as this gap (paired with an electrolyte solution) allow for the transfer of voltage. It’s much more precise compared to methods such as punch deburring or tumbling deburring, and allows holes, cross holes, and intersections to be deburred easily. However, this method is limited to a small variety of materials seeing as some don’t contain the required levels of conductivity.

Thermal Deburring

The thermal deburring technique is carried out by placing parts in a pressurized chamber and setting off a series of controlled combustions, which essentially melt off any burrs or surface imperfections. The overall structure of the part/gear in the chamber isn’t harmed due to how momentary these mini explosions are, however the risk of excessive heat damage is still present. Once the burrs are removed, the part/gear is left with a thin film coating its surface and it must be cleared off before it is further processed. While efficient when it comes to removing multiple burrs/surface imperfections at once, it also lacks the necessary precision required by some industries, such as the aerospace industry.  

Machine Deburring

Machine deburring is the most effective method of deburring when it comes to timeliness, cost efficiency, and precision, and has been gaining popularity as the demand for all three of these factors has grown dramatically over the course of the last few years. Machine deburring extends to both CNC machines and finishing machines, such as the MAX System from James Engineering, a high precision deburring and chamfering machine. CNC machines are most efficient when it comes to cutting parts, but they also have limited deburring capabilities. The MAX System and its one-of-a-kind technologies allows the machine to deburr and chamfer, radius, wash, and brush a part concurrently. This is due to its multi-tooling feature, which is customizable to any company’s needs. It also features an 11-axis overhead gantry system, making any angle reachable. The MAX is a great option for both parts and gears of any size and any complexity, and with Focused Deburring (a technology unique to James Engineering), burrs can be targeted—something only James Engineering finishing systems are capable of.

Which one is right for you?

These eight methods of deburring are used for a wide range of industries, parts, and gears, and each have their own pros and cons. Finding the right one for your company ultimately depends on the volume at which your shop is producing, and what parts/gears you produce. The lower your shop’s volume is, and the simpler your parts, methods such as hand deburring can be a reasonable choice. If your shop is producing at a high volume and working with a wide array of gears/parts of a variety of materials, a specialized finishing machine such as the MAX System is the most time and cost-effective move to make. Doing your own research is important, and you know your shop’s needs the best… but you can never go wrong with the MAX.

Innovating Tomorrow

Within the walls of James Engineering, a dedicated engineer works tirelessly to perfect vital components and assemblies. Dave Schlosser, head engineer for the Coloradoan OEM shop, and his crew of engineers team up to draw, assemble, and manufacture the one-of-a-kind deburring machines sold by James Engineering. But Schlosser’s career in engineering began way before he joined the J.E. family.

“I started when I was 13 in my dad’s garage; he welded, so I’d help him with welding. Then I wanted to be a machinist because my dad was one,” Schlosser states. He got his foot in the industry’s door early, which eventually nudged him to go to school for machining. Eventually, he dipped his toes into quality control before migrating into the engineering department for a different company, which was eventually bought out.

After years of completing personal projects, such as an adapter plate for his Volkswagen transmission, Schlosser realized not only was he a talented engineer, but a creator at heart. So when he found his job at James Engineering, he knew it would be the perfect position to nurture his creative desires. Schlosser gives a little insight as to what his daily tasks consist of:

“I lead the engineering team. We got a couple of interns and full-time guys. I’ll also run what goes through the machine shop and help prioritize [the projects].” When asked how the position keeps his creativity flowing, he explains, “We do drawing revisions, part revisions, and new product development.”

Updating assemblies and part drawings is crucial—this process ensures that both the engineering department and shop floor are on the same page before pieces/assemblies are completed. Concise drawings create clear communication between the two groups, which ultimately does three things: decreases the number of errors made in production, increases shop efficiency, and allows for the creation of new products. Schlosser is central to this procedure. “We started making our own cogged pulleys,” Schlosser explains, “Belt pulleys, not like gears. [These] pulleys have slots in them for grooved belts. It’s like a timing belt in a car, which has little cogs in them. This eliminates backlash in our machines. We just started doing these about six months ago.”

While this process gives Schlosser the outlet he’s always wanted, it has proven to be the biggest test for him during his time at James Engineering. “Because we are a small company, there’s a lot of tribal knowledge of how things work. It’s not quantified in a lot of cases in drawings, so that’s a big challenge—getting that knowledge from somebody’s head and getting it put [on paper].”

Despite its trials, this shared knowledge is one of the most unique parts about working at James Engineering. “There’s tech here that you don’t see anywhere else. And Jim’s got [decades] of knowledge, so I learn from him every day.” Jim Richards is the founder of the company and works closely with the engineers every day. “I take what I know and keep adding on to that.”

Schlosser has collected new information and experience throughout his whole career. The mechanical engineering industry has only continued to evolve, introducing new technology and methods to its workers at astounding rates. “When I first got into the industry, CNC machines were brand new. Now, everything is computer controlled instead of being done by hand,” Schlosser reflects. With CNC machining giving manufacturers the upper hand in efficient and speedy production, engineers such as Schlosser can turn all their ideas into reality. ‘There’s a lot of stuff I want to develop with the tech here. Jim and I talked about building a table with our gantry system where you can plug in a router and a laser. This would be used instead of having multiple machines that do the same thing. I also want to do a whole series of our own products that don’t even necessarily have to do with deburring.”

With new waves of engineers pouring into the industry every year, mechanical engineering will further evolve. Schlosser offers them his seasoned advice: “If you’re going to be a mechanical engineering designing mechanical parts, learn machining! You don’t have to be an expert at it, just know how to make parts because then you can make drawings a lot faster. Go get a job at a machine shop just so you can learn how materials are cut. With experience like that, you’ll be years ahead of your peers who also just got out of school.” As somebody who worked in a machine shop before entering the engineering field, Schlosser knows firsthand how effective this method can be. “Learn how whatever you’re working on is made, whether it’s plastic, metals, etc.”

The mechanical engineering field is one that provides countless learning opportunities, and Schlosser cannot stress enough how important it is to take each one you can get your hands on. By doing so himself, he has worked a plethora of jobs that have built upon his knowledge every day. Schlosser’s time at James Engineering has not only taught him about hydraulics and pneumatics, but it has strengthened his abilities to problem solve and lead a team. Schlosser is coming up on his third year at the shop, and is given the freedom to do what he loves best—create.

“It all comes from your head, and then it’s in your hands. That’s what’s really cool about mechanical engineering.”

A cool career, indeed.

Part Finishing 101: A Beginner's Guide

Every piece of machinery is made up of a thousand smaller pieces all continuously working together to accomplish the same goal. Every single one of these pieces need to go through the part finishing process, which ensures they work correctly and keep the overall operation running smoothly. “Part finishing” is an umbrella term for all the individual processes and techniques that go into the ultimate completion of these parts/gears.

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Machining

First, let’s start with machining. This is where gears/parts are initially manufactured out of blocks of raw material. CNC (computer numerical control) machines do most of this work, and there are multiple different kinds of CNC machines, such as milling machines, lathes and turning machines, laser cutting machines, etc. Excess material is carved away by these machines to reveal the rough shape of whatever gear/prismatic part is being created. Once this first step is completed, the nitty-gritty side of part finishing begins.

Deburring

Deburring is the process of removing burrs from the edges and surfaces of these freshly cut parts/gears. Burrs are sharp bits of excess metal that will eventually ruin the integrity and overall quality of whatever part/gear they’re stuck to. This process can be done by hand, in a CNC machine, or a machine made specifically for deburring*, such as a James Engineering machine. Deburring is one of the most crucial aspects of part finishing, as many other processes cannot be done if a part or gear is not deburred properly.

Surface Grinding

This process creates smooth surface finishes on metal and non-metal parts alike. It’s an abrasive process which uses grinding wheels to shave down any surface impurities that might affect the functionality and aesthetic of a gear/part. Grinding wheels (add link to website page here) come in a variety of sizes and materials, which directly determine a wheel’s grinding intensity. Grinding surfaces are crucial when it comes to achieving tight part tolerances, as it ensures a part will fit perfectly within its environment. Surface grinding will also rid a part/gear of any corrosive layers that may negatively affect its overall durability.

Polishing

Polishing is done to further smoothen a part’s surface. What makes polishing different from surface grinding is that it’s meant to enhance surface quality, whereas grinding is used to remove extra material. Polishing is also an abrasive process, and it uses polishing pastes and abrasive pads. Polished parts are reflective and more resistant to corrosion, which makes it a crucial step in the finishing process for items such as car bumpers, medical equipment, mirrors, and more.

Buffing

Many people get buffing and polishing confused—but it’s fair considering how alike these two processes are. What makes them different is their levels of aggression. Buffing is the more aggressive of the two, and can actually remove surface material if done too hard. It can be used to remove shallow scratches, and unlike polishing, it will not leave a highly reflective surface. Buffing is frequently used in the automotive, jewelry, and electronic industries.

Chamfering

This step of the part finishing process is extremely important, especially for pieces with right-angled edges. Chamfering is when these edges are cut at a slope, which later makes assembly easier and reduces the amount of stress risers within a gear/part. Sharp, non-chamfered edges can snap and break off, leading to loose material floating throughout a machine. This debris could ultimately affect the efficiency of the entire machine, and even cause it to fail completely. When edges are chamfered, the likelihood of such an occurrence is reduced drastically. It will also ensure that pieces fit together more snugly, reducing the risk of the parts themselves becoming too loose.

Brushing

Brushing can be categorized as a type of deburring, as it can technically get rid of excess burrs left on the surfaces of parts. But that’s not its man job—brushing is used as a way to further perfect part surfaces, as it preps parts for coatings and rids them of any external contaminants, such as oils, dirt, residue, etc. It is also a very precise process in the sense that if only one small section of a part/gear needs further surfacing, a brush can stay focused on that specific spot without affecting the rest of the gear/part’s body. An important thing to remember when it comes to metal brushing is that certain brushes must be used on certain metals; for example, stainless steel can only be brushed with steel brushes. But other materials, such as rubber and leather, can also be brushed if need be.

Sandblasting

This process is also known as abrasive blasting, as it can be done with many other substances other than sand, such as glass beads, water, dry ice, and compressed air. This is another technique used to smoothen, decontaminate, and shape surfaces. This technique of part finishing comes from the naturally occurring phenomenon called aeolian erosion, which is when an environment’s geography is changed and shaped by consistent winds. Blasting is done manually when a blasting substance is mixed with air in a pressurized chamber and dispensed through an abrasive-proof handheld nozzle.

Washing

The washing process works exactly how you’d think it would—a mixture of hot water, solvent, or washing fluid are dispensed either by hand or by a machine over freshly-processed parts to clean them of excess swarf. It’s important to wash parts of debris because, as mentioned above, debris can drastically decrease the effectiveness of a part/gear and the greater machine it was assembled into. In order to avoid corrosion or rusting, special fluids must be used to protect both the part being washed and the machine doing said washing.

Overall

Machining, deburring, chamfering, washing, brushing, surface grinding, polishing, buffing, and sandblasting are the most common part finishing processes in the manufacturing industry, but there are still a variety of methods used that were not mentioned. Each process has its own unique use, and it’s crucial that manufacturers understand what method will produce the strongest outcome for a part or gear.

How James Engineering Part Finishes

Here at James Engineering, we are experts when it comes to the varying methods of part finishing. We manufacture and sell all all-encompassing surface finishing and chamfering machine known as the MAX System, and it’s got you covered completely—the MAX can deburr, chamfer, wash, brush, and even radius parts/gears of various sizes. The best part is the MAX can carry out multiple processes at once, which exponentially cuts down on processing time and leads to a higher production volume.

If you’d like to experience the effortless efficiency of a multitasking finishing fiend, contact us at Sales@James-Engineering.com and we will send you a quote!

*For being such a vital part in the finishing process, deburring machines are an extremely niche market of their own. James Engineering specializes in deburring and chamfering machines and offers a variety of systems at competitive pricing. Click here to learn more about the different kind of systems we manufacture.

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The Matter of The Sprocket

Sprockets are an extremely common and useful gear used in everyday applications, such as bicycles and motorcycles. Some of the earlier automobile models even used them, taking inspiration from the mechanics of bikes!

A sprocket transmits rotary motion by locking its many teeth into a chain and driving it and therefore moving any other parts also connected to said chain. Sprocket gears can have multiple strands, meaning they can attach to multiple different chains at once, and have anywhere from 17 to 114 teeth. Anything above or below those numbers are inefficient.

Sprockets can either be made with or without hubs. Hubs are the thickness seen on either face of the sprocket and are separate from the teeth. The thicker the hub, the more torque the sprocket can transfer.

There are a few types of sprockets, each needed for different applications:

·      Type A: These are flat with plain bores. This means they have no hubs at all.

·      Type B: These sprockets have only one hub on one of their faces.

·      Type C: These have two hubs, one on each face of the sprocket, and they are both equal in their thickness.

·      Type D: These sprockets also have two hubs, one on each of its faces, but one is thicker than the other, offsetting it just like a Type B sprocket is offset.

If the wrong kind of sprocket is used (i.e. if its hub is too thick to fit snugly against equipment, or if its number/thickness of teeth don’t match with a chain’s tooth pitch), the entire chain assembly can fall apart, or cause time and money consuming shutdowns.

Sprockets pose a unique challenge when it comes to finishing them properly.

These big-or-little gears require intense attention to detail, which is vital for their function, but time consuming and costly. Normally, a sprocket would have to be deburred, chamfered, and brushed by hand or in a manual machine. These options are fine in some scenarios, but for a production business, these options will ultimately slow you down and disrupt the flow of operations.

Before

After

A machine such as the MAX System greatly outpaces any manual and hand operations, especially when sprockets are involved. The MAX will process a sprocket of any size in up to 10 seconds. Two major features of the MAX allow for this amazing processing time: its capabilities to run multiple tools concurrently, and its ability to program part adjustments for future use.

The recipe programming of the MAX singlehandedly makes it a standout machine. It will take operators anywhere from 5 to 10 minutes to adjust the machine to a specific part, and once they have, the MAX will remember said adjustments and save them for future use. It can save a multitude of different part recipes, making it ridiculously easy to change out parts, no matter how drastic size differences/requirements are between them. Because sprockets are such tricky parts, this saves businesses an abundance of precious time.

The MAX also offers both wet and dry options. The machine will run beautifully either way, so it’s ultimately a matter of preference. However, the wet option is fantastic if you’re worried about flammable debris and how it can affect your machine. The wet MAX comes with rust-inhibiting solution so as to not damage machine or part, and it quickly washes away any debris before it becomes an issue. No debris will ever get caught between the teeth of sprockets of any size.

Sprockets can be a manufacturer’s nightmare, but they don’t have to be. The MAX System by James Engineering is built with efficiency and precision in mind, meaning it can take any sprocket with ease.

Watch the video below to see how all of this works in real-time.

High speed precision deburring for quick production

The Dynamic Duo

As the demand for parts grows exponentially within the manufacturing industry, so does the need for expert deburring and chamfering. James Engineering manufactures an all-purpose finishing system known as the MAX System that is meant to be paired with CNC machines to produce parts of the highest caliber.

“The MAX is meant to compliment CNC machines,” explains Scott Richards, Vice President of James Engineering. “The MAX allows CNC machines to do what they do best: make parts.”

While CNC machines can deburr parts, they tend to be choppy, aggressive, and slow at it; their primary function is to cut. This means high-volume shops are extremely limited when it comes to both the quality and quantity of parts they’re producing (that is if they rely on CNC machines to deburr as well). The MAX is the solution to this problem—it leaves cutting to the CNC machines and does everything else. “We’re not trying to make a metal cutting machine, or a part manipulator. We’re making a machine that does a delicate job quickly in a way that hand deburring, and CNC machines, can’t,” says Richards. So once the CNC machines can focus solely on cutting, a higher volume of parts can be produced in one day, ultimately heightening a company’s productivity as well as increasing their overall part quality.

Before

This is what a part would look like just after it’s been cut. All those ridges are bits of excess metal that need to be deburred off.

After

This is what a part would look like after it’s been deburred, chamfered, brushed, washed, and surfaced by the MAX.

Not only does the MAX make overall processing easier, but the machine itself is easily operatable, especially for those who have prior experience with CNC machines. “Within four minutes anybody could learn how to use the machine,” Richards states, “We teach these machines to move into position conversationally, have it catch that point, then move to another position. This is unlike CNC machines, or even robots. If someone new wanted to run a CNC machine, they’d have to understand the language the program is written in; we do not run M- or G-code, we use conversational programming.”

Deburring in a CNC machine can be inaccurate and slow-moving—but that’s because deburring isn’t the main function of a CNC, cutting is. The whole purpose of the MAX is to take the weight of deburring off CNC machines. So while the CNCs focuses on expertly cutting parts, the MAX deburrs, chamfers, brushes, washes, and surfaces all in one go after said parts have gone through the CNC. The MAX will pick up a CNC’s slack, and vice versa, making them the perfect pair. The duo will drastically reduce cycle times while still producing a high volume of expertly processed parts with focus, and without the sacrifice of integrity. For any shops out there running into issues with CNC deburring, or for companies who would simply like to increase their productivity overall, investing in the MAX is the next step you need to make.

Everyone needs a best friend, even machines. Give your CNC its best buddy today and inquire at Sales@James-Engineering.com as to how you can bring your MAX home.