{ "slug": "deburring-methods", "title": "Deburring Methods for CNC Parts: 15 Processes Compared", "description": "Fifteen deburring processes compared by edge type, burr size, edge radius, Ra effect and cost tier, with worked cycle-time examples and cross-hole guidance.", "lang": "en", "tables": [ { "caption": "Deburring and edge-breaking methods compared (15 processes)", "columns": [ "Method", "Edge type", "Materials", "Max burr size", "Edge break / R", "Ra effect", "Cost tier", "Equipment threshold", "Source" ], "rows": [ { "Method": "Manual (file / scraper / blade)", "Edge type": "external edges, fixed-angle chamfer; not thin-wall / internal cross-hole / critical radius", "Materials": "all metals", "Max burr size": "no unified limit (gap)", "Edge break / R": "edge break 0.2–0.5 mm; skilled ±0.05 mm", "Ra effect": "hand polishing edge break ≤ 0.01 mm; Ra depends on tool", "Cost tier": "2", "Equipment threshold": "low; hand tools €10–50", "Source": "S1, S19" }, { "Method": "CNC in-machine chamfer / edge tool", "Edge type": "external edges, bore entrances, tool-reachable edges", "Materials": "all metals", "Max burr size": "not specified (gap)", "Edge break / R": "90° chamfer 0.1–2.0 mm; ball end mill R 0.1–0.5 mm", "Ra effect": "depends on cutter; minimal Ra change", "Cost tier": "2", "Equipment threshold": "medium; needs CNC + programming", "Source": "S19" }, { "Method": "Rotary brush (incl. in-machine)", "Edge type": "external, threads, tight corners, light internal features", "Materials": "all metals", "Max burr size": "light burrs only (gap)", "Edge break / R": "fine brush edge break 0.01–0.02 mm", "Ra effect": "improves Ra; micro-brush 1,000–3,000 rpm", "Cost tier": "2", "Equipment threshold": "low–medium; fits CNC tool changer", "Source": "S1" }, { "Method": "Barrel tumbling", "Edge type": "external edges of small parts", "Materials": "metals, some plastics", "Max burr size": "small burrs (gap)", "Edge break / R": "larger edge radius; numeric R not given", "Ra effect": "coarser than vibratory; Ra range not given", "Cost tier": "3", "Equipment threshold": "medium; rotating barrel 20–45 rpm", "Source": "S10" }, { "Method": "Vibratory finishing", "Edge type": "external + media-reachable internal, slots, cross-holes", "Materials": "all metals", "Max burr size": "stainless burr ≈ 75–80 µm (retrieval-index transcription)", "Edge break / R": "controlled edge R 0.05–0.3 mm", "Ra effect": "Ra 3.2 → 0.8 µm; range 0.4–1.6 µm", "Cost tier": "3", "Equipment threshold": "medium; cycle 20–120 min", "Source": "S9, S10, S42" }, { "Method": "Centrifugal barrel", "Edge type": "small precision parts, external", "Materials": "metals", "Max burr size": "small–medium burrs", "Edge break / R": "numeric R not given", "Ra effect": "Ra 0.2–0.8 µm", "Cost tier": "3", "Equipment threshold": "medium–high; deburr 15–45 min", "Source": "S10, S13" }, { "Method": "Centrifugal disc", "Edge type": "small parts, high volume", "Materials": "metals", "Max burr size": "small burrs", "Edge break / R": "numeric R not given", "Ra effect": "Ra 0.2–0.8 µm; low-Ra finish", "Cost tier": "3", "Equipment threshold": "medium–high; about 2 h deburr, auto-unload", "Source": "S14, S15" }, { "Method": "Drag finishing", "Edge type": "external edges of cutting tools, round parts", "Materials": "carbide, hardened steel", "Max burr size": "micro edge burrs", "Edge break / R": "60 min: Ø6 mm tool R ≈ 18 µm; Ø8 mm ≈ 20 µm", "Ra effect": "roughness improvement rate reported", "Cost tier": "3", "Equipment threshold": "medium–high; fixtured drag through media", "Source": "S16" }, { "Method": "Abrasive flow machining (AFM)", "Edge type": "internal passages, cross-holes, deep cavities", "Materials": "all metals", "Max burr size": "thin burrs (gap)", "Edge break / R": "uniform edge R 0.02–0.05 mm", "Ra effect": "fine internal Ra; extrusion pressure 10–200 bar", "Cost tier": "5", "Equipment threshold": "high; dedicated machine + tooling", "Source": "S1, S17, S23" }, { "Method": "Electrochemical deburring (ECD)", "Edge type": "internal cross-holes, inaccessible intersections", "Materials": "conductive metals only", "Max burr size": "up to 0.5 mm", "Edge break / R": "edge R 0.05–0.2 mm (single secondary source); control ±0.05 mm", "Ra effect": "Ra 2–4 µm; no mechanical force", "Cost tier": "4", "Equipment threshold": "high; power supply + targeted cathodes", "Source": "S6, S7, S21" }, { "Method": "Thermal energy method (TEM)", "Edge type": "all internal + external edges simultaneously", "Materials": "steel, stainless, cast iron best; not aluminium / most plastics", "Max burr size": "thin burrs / flash", "Edge break / R": "edge break 0.02–0.05 mm", "Ra effect": "oxide residue needs post-cleaning", "Cost tier": "5", "Equipment threshold": "high; chamber equipment €300k–800k", "Source": "S1, S3, S19" }, { "Method": "Laser deburring (SLD)", "Edge type": "sheet-metal external edges, defined radii", "Materials": "metals", "Max burr size": "thin burrs remelted", "Edge break / R": "minimum achievable R ≈ 0.55 mm", "Ra effect": "remelted edge; no tool wear", "Cost tier": "4", "Equipment threshold": "high; laser source + optics + fixturing", "Source": "S33, S34" }, { "Method": "High-pressure water jet (HPW)", "Edge type": "cross-holes, deep holes, tap holes (line of sight)", "Materials": "all metals; limited on ductile burrs", "Max burr size": "loose / light-adhering only", "Edge break / R": "no R value; firm burrs remain", "Ra effect": "no thermal / chemical stress; cleaning combined", "Cost tier": "4", "Equipment threshold": "high; pump + NC multi-axis nozzle", "Source": "S19, S24, S26" }, { "Method": "Chemical deburring (electroless)", "Edge type": "complex small parts, hard-to-reach areas", "Materials": "steel, aluminium, stainless (solution-specific)", "Max burr size": "up to a few tenths of mm", "Edge break / R": "leveling; no fixed R", "Ra effect": "surface leveling via peak-valley potential difference", "Cost tier": "3", "Equipment threshold": "medium; tanks + chemical bath management", "Source": "S36, S37, S38" }, { "Method": "Cryogenic + shot blast", "Edge type": "external flash / burr", "Materials": "rubber, plastic, die-cast metals", "Max burr size": "thin flash; precision to 0.01 mm", "Edge break / R": "clean flash break; part dimensions retained", "Ra effect": "minimal to none on base surface", "Cost tier": "4", "Equipment threshold": "high; insulated chamber + blast wheel", "Source": "S28, S30, S31, S52" } ] }, { "caption": "What edge break can a skilled manual deburring operator hold consistently?", "columns": [ "Burr size class", "Burr height", "Typical scenario", "Source" ], "rows": [ { "Burr size class": "Precision burr", "Burr height": "< 0.02 mm", "Typical scenario": "aerospace / medical critical edges", "Source": "S2" }, { "Burr size class": "Minor burr", "Burr height": "0.02–0.05 mm", "Typical scenario": "general precision machining", "Source": "S2" }, { "Burr size class": "Moderate burr", "Burr height": "0.05–0.15 mm", "Typical scenario": "standard milled / drilled edges", "Source": "S2" }, { "Burr size class": "Heavy burr", "Burr height": "> 0.15 mm", "Typical scenario": "dull tool / ductile material / heavy cut", "Source": "S2" } ] }, { "caption": "Which deburring method gives the smallest edge break for threads and tight corners?", "columns": [ "Edge location", "First choice", "Alternative", "Not recommended", "Source" ], "rows": [ { "Edge location": "External straight edge / fixed chamfer", "First choice": "CNC in-machine chamfer tool", "Alternative": "manual, rotary brush", "Not recommended": "TEM for a simple edge (over-cost)", "Source": "S19" }, { "Edge location": "External 3D freeform edge", "First choice": "ball end mill / disc brush", "Alternative": "robotic compliant spindle", "Not recommended": "rigid chamfer tool", "Source": "S19" }, { "Edge location": "Bore entrance / bore internal surface", "First choice": "Flex-Hone (Ø4–960 mm)", "Alternative": "rotary brush", "Not recommended": "rigid tool (cannot follow bore)", "Source": "S19" }, { "Edge location": "Cross-hole / intersection", "First choice": "ECD or Flex-Hone", "Alternative": "TEM, AFM, HPW", "Not recommended": "manual (inconsistent), rigid tool", "Source": "S19, S21" }, { "Edge location": "Deep cavity / internal passage", "First choice": "AFM", "Alternative": "TEM, ECD", "Not recommended": "brush / belt (cannot reach)", "Source": "S1, S17" }, { "Edge location": "Hidden / inaccessible burr", "First choice": "TEM", "Alternative": "ECD", "Not recommended": "line-of-sight methods", "Source": "S3, S19" }, { "Edge location": "Screw / thread edge", "First choice": "fine rotary brush", "Alternative": "ECD", "Not recommended": "aggressive belt (damages thread)", "Source": "S1" } ] }, { "caption": "How does vibratory finishing change edge radius and surface roughness?", "columns": [ "Parameter", "Value", "Source" ], "rows": [ { "Parameter": "Ceramic media standard cycle", "Value": "40–60 min, edge R 0.05–0.15 mm", "Source": "S9" }, { "Parameter": "Extended cycle for R up to 0.3 mm", "Value": "90–120 min", "Source": "S9" }, { "Parameter": "Aluminium edge break 0.10–0.20 mm, 10 mm ceramic", "Value": "30–60 min", "Source": "S11" }, { "Parameter": "Deburring cycle range", "Value": "20–60 min", "Source": "S12" }, { "Parameter": "Radiusing cycle range", "Value": "30–90 min", "Source": "S12" }, { "Parameter": "Material removal, ceramic", "Value": "0.01–0.05 mm per surface", "Source": "S9" }, { "Parameter": "Material removal, plastic media", "Value": "0.002–0.01 mm per surface", "Source": "S9" }, { "Parameter": "Media-to-part volume ratio", "Value": "3:1–5:1 (precision up to 6:1+)", "Source": "S9, S10" }, { "Parameter": "Bowl load fill", "Value": "60%–70%", "Source": "S9" }, { "Parameter": "Stainless burr the process is sized for", "Value": "≈ 75–80 µm (retrieval-index transcription, not directly verified)", "Source": "S42" }, { "Parameter": "Removal from part diameter or thickness", "Value": "7–25 µm", "Source": "S42" }, { "Parameter": "Rotary brush, aluminium", "Value": "1,000–1,500 rpm, 15–30 µm compound", "Source": "S1" }, { "Parameter": "Rotary brush, hardened steel", "Value": "2,000–3,000 rpm, 3–9 µm diamond", "Source": "S1" } ] }, { "caption": "What is the typical stainless burr thickness a vibratory process is sized for?", "columns": [ "Sizing parameter", "Value", "Source" ], "rows": [ { "Sizing parameter": "Typical stainless burr", "Value": "≈ 75–80 µm (76 µm in the retrieval index; not directly verified)", "Source": "S42" }, { "Sizing parameter": "Removal per cycle", "Value": "7–25 µm", "Source": "S42" }, { "Sizing parameter": "Centrifugal barrel vs vibratory, same work", "Value": "15–45 min vs 4–24 h", "Source": "S13" }, { "Sizing parameter": "Centrifugal disc deburr", "Value": "about 2 h, auto-unload", "Source": "S14, S15" } ] }, { "caption": "How much burr can electrochemical deburring remove and what radius does it leave?", "columns": [ "Parameter", "Conventional ECD", "Cross-hole study", "Source" ], "rows": [ { "Parameter": "Applied voltage", "Conventional ECD": "12–24 V (DC supply 8–30 V)", "Cross-hole study": "50–100 V", "Source": "S6" }, { "Parameter": "Current density", "Conventional ECD": "5–10 A/cm²", "Cross-hole study": "30–200 A/cm²", "Source": "S6" }, { "Parameter": "Interelectrode gap", "Conventional ECD": "0.1–0.3 mm", "Cross-hole study": "0.1–0.7 mm", "Source": "S6" }, { "Parameter": "Time", "Conventional ECD": "5–100 s", "Cross-hole study": "—", "Source": "S6" }, { "Parameter": "Typical cycle", "Conventional ECD": "30–45 s; about 20 s multi-hole", "Cross-hole study": "—", "Source": "S6, S21" }, { "Parameter": "Electrolyte pressure", "Conventional ECD": "0.3–0.5 MPa", "Cross-hole study": "—", "Source": "S6" }, { "Parameter": "Burr height removed", "Conventional ECD": "up to 0.5 mm", "Cross-hole study": "—", "Source": "S6" }, { "Parameter": "Edge radius left", "Conventional ECD": "R 0.05–0.2 mm (single secondary source — see note above)", "Cross-hole study": "—", "Source": "S6" } ] }, { "caption": "What are the typical voltage and current density for electrochemical deburring?", "columns": [ "Work material", "Electrolyte", "Source" ], "rows": [ { "Work material": "Carbon / low-carbon steel", "Electrolyte": "5%–15% or 2%–2.5% NaNO3", "Source": "S6" }, { "Work material": "Copper alloys", "Electrolyte": "5%–15% NaNO3", "Source": "S6" }, { "Work material": "Aluminium alloys", "Electrolyte": "5%–20% NaNO3", "Source": "S6" }, { "Work material": "Stainless steels", "Electrolyte": "5% NaNO3 + 0.5% NaCl", "Source": "S6" }, { "Work material": "Electrolyte supply pressure", "Electrolyte": "0.3–0.5 MPa; tool gap 0.1–0.3 mm; tip overlap 1.5–2 mm", "Source": "S6" } ] }, { "caption": "How fast is a thermal energy method (TEM) cycle?", "columns": [ "Parameter", "Value", "Source" ], "rows": [ { "Parameter": "Combustion temperature", "Value": "2,500–3,500 °C, milliseconds", "Source": "S3" }, { "Parameter": "Fuel gas", "Value": "methane + oxygen, pressurized chamber", "Source": "S3, S4" }, { "Parameter": "Cycle excluding load/unload", "Value": "less than 1 minute; active burn < 1 s", "Source": "S3, S1" }, { "Parameter": "Edge break", "Value": "0.02–0.05 mm; over-burn can round to 0.05 mm", "Source": "S1" }, { "Parameter": "Removed burr amount set by", "Value": "gas volume, burr thickness, material heat-transfer rate, fuel-oxygen ratio", "Source": "S3" } ] }, { "caption": "Which materials are not suitable for thermal deburring?", "columns": [ "Material", "Preferred methods", "Caution / limitation", "Source" ], "rows": [ { "Material": "Carbon / low-carbon steel", "Preferred methods": "CNC tool, vibratory, ECD, TEM, chemical", "Caution / limitation": "chemical bath needs stock-loss allowance", "Source": "S6, S36" }, { "Material": "Stainless steel", "Preferred methods": "vibratory, ECD, TEM, AFM", "Caution / limitation": "chemical uses nitric acid; TEM leaves oxide to clean", "Source": "S3, S38" }, { "Material": "Aluminium", "Preferred methods": "plastic media, rotary brush, Flex-Hone, chemical (NaOH)", "Caution / limitation": "TEM generally unsuitable; hard ceramic media can impinge a soft surface", "Source": "S1, S38" }, { "Material": "Copper / brass", "Preferred methods": "plastic / steel media, ECD, vibratory", "Caution / limitation": "avoid aggressive ceramic on soft brass", "Source": "S6, S10" }, { "Material": "Hardened steel / carbide", "Preferred methods": "diamond brush, drag finishing, AFM, ECD", "Caution / limitation": "needs fine abrasive (3–9 µm diamond)", "Source": "S1, S16" }, { "Material": "Titanium", "Preferred methods": "AFM, ECD, fine media", "Caution / limitation": "low conductivity / reactivity needs a tuned electrolyte", "Source": "S17" }, { "Material": "Rubber / elastomer", "Preferred methods": "cryogenic + shot", "Caution / limitation": "temperature must fall below the material Tg", "Source": "S31" }, { "Material": "Plastic / nylon", "Preferred methods": "cryogenic, fine brush, HPW", "Caution / limitation": "TEM burns plastic; ECD impossible (non-conductive)", "Source": "S19, S30" }, { "Material": "Die-cast metal", "Preferred methods": "cryogenic (warm range), plastic media", "Caution / limitation": "protect the porous cast skin before plating", "Source": "S29, S51" } ] }, { "caption": "What pressure does high-pressure water deburring typically use?", "columns": [ "Source / equipment", "Pressure range", "Note" ], "rows": [ { "Source / equipment": "HPWD typical (S26)", "Pressure range": "5,000–7,500 psi (34–52 MPa), up to 15,000 psi (103 MPa)", "Note": "retrieval-index transcription, not directly verified; report BDX-613-2421 (1980) cited by DOI" }, { "Source / equipment": "Sugino JCC (S24)", "Pressure range": "up to 50 MPa", "Note": "CNC nozzle, cross / deep / tap holes" }, { "Source / equipment": "Sugino JDM (S25)", "Pressure range": "up to 70 MPa", "Note": "cross-holes, gears" }, { "Source / equipment": "PrecisionPro (S19)", "Pressure range": "300–2,500 bar (30–250 MPa)", "Note": "deburring tier — loose or light-adhering burrs only; firm burrs remain" }, { "Source / equipment": "Sinobakr (S27)", "Pressure range": "5–50 MPa stepless", "Note": "99% removal; 1–5 µm filtration; automotive parts" }, { "Source / equipment": "WOMA UHP (S55)", "Pressure range": "up to 4,000 bar (400 MPa; 58,000 psi)", "Note": "UHP pump ceiling — cutting / heavy-cleaning tier, not a deburring routine parameter" } ] }, { "caption": "What is the minimum edge radius achievable by laser deburring?", "columns": [ "Parameter", "Value", "Source" ], "rows": [ { "Parameter": "Laser source", "Value": "5 kW diode / 5 kW Nd:YAG", "Source": "S33, S35" }, { "Parameter": "Feed rate", "Value": "up to 9 m/min", "Source": "S33" }, { "Parameter": "Minimum achievable edge radius", "Value": "about 0.55 mm (PDF not re-verified online)", "Source": "S34" }, { "Parameter": "Edge forming capacity, high-strength steel", "Value": "increased by more than 240%", "Source": "S33" } ] }, { "caption": "How do chemical and electrochemical deburring differ?", "columns": [ "Process", "Driving force", "Typical cycle", "Where it works" ], "rows": [ { "Process": "Chemical deburring (electroless)", "Driving force": "bath chemistry, no power", "Typical cycle": "about 60 s", "Where it works": "" }, { "Process": "Electrochemical deburring (ECD)", "Driving force": "DC supply + targeted cathodes + electrolyte", "Typical cycle": "20–45 s per cycle", "Where it works": "" }, { "Process": "Terminology conflict", "Driving force": "some pages call ECD chemical deburring", "Typical cycle": "—", "Where it works": "" }, { "Process": "Chemical solutions", "Driving force": "acid or alkali per alloy", "Typical cycle": "—", "Where it works": "" } ] }, { "caption": "Should deburring happen before or after anodizing?", "columns": [ "Step", "Operation" ], "rows": [ { "Step": "1", "Operation": "CNC machine to drawing dimensions" }, { "Step": "2", "Operation": "Deburr and clean" }, { "Step": "3", "Operation": "Pre-treatment (etch, de-smut)" }, { "Step": "4", "Operation": "Anodize to specified type and thickness" }, { "Step": "5", "Operation": "Dye (optional)" }, { "Step": "6", "Operation": "Seal" }, { "Step": "7", "Operation": "Inspect" } ] }, { "caption": "How much of total part cost can deburring consume?", "columns": [ "Source", "Share", "Scope" ], "rows": [ { "Source": "SpecForge / IQS (S39)", "Share": "about 30%", "Scope": "precision aerospace" }, { "Source": "SpecForge (S39)", "Share": "15%–20%", "Scope": "automotive" }, { "Source": "Ramachandran survey (S41, JMPT 44(1–2) 1994, DOI 10.1016/0924-0136(94)90033-7)", "Share": "5%–15%", "Scope": "average edge/surface finishing" }, { "Source": "Dingzhu / AFS (S43)", "Share": "5%–12%", "Scope": "castings" } ] }, { "caption": "At what volume does CNC-integrated brush or Flex-Hone deburring pay off versus manual work?", "columns": [ "Production volume", "Recommended approach", "Break-even logic", "Source" ], "rows": [ { "Production volume": "Prototype / one-off (< 50 pcs)", "Recommended approach": "manual blade / file", "Break-even logic": "no investment, flexible", "Source": "S19" }, { "Production volume": "Small batch (about 50 pcs/month up)", "Recommended approach": "CNC-integrated Flex-Hone / brush", "Break-even logic": "break-even vs manual around 50 pcs/month", "Source": "S19" }, { "Production volume": "Medium batch (hundreds)", "Recommended approach": "vibratory / centrifugal batch finishing", "Break-even logic": "labour cost per part drops above ~20 pcs/batch", "Source": "S9" }, { "Production volume": "High volume (>10,000/day)", "Recommended approach": "TEM or dedicated deburring system", "Break-even logic": "one cycle hits all edges; high throughput", "Source": "S19" }, { "Production volume": "Continuous flow (e.g. crankshafts)", "Recommended approach": "linear continuous vibrator", "Break-even logic": "under 1 min per part, 60+ pcs/h", "Source": "S44" } ] }, { "caption": "How does cryogenic deflashing affect part dimensions and surface?", "columns": [ "Parameter", "Value", "Source" ], "rows": [ { "Parameter": "Machine cooling range", "Value": "−130 °C to +50 °C; operating down to about −150 °C", "Source": "S29, S30" }, { "Parameter": "Liquid nitrogen boiling point", "Value": "about −196 °C", "Source": "S30" }, { "Parameter": "EPDM glass-transition Tg", "Value": "−55 °C", "Source": "S31" }, { "Parameter": "SBR Tg", "Value": "−40 °C", "Source": "S31" }, { "Parameter": "NBR Tg", "Value": "−30 °C", "Source": "S31" }, { "Parameter": "Example batch", "Value": "7 kg, −70 °C, 8 min, wheel 6,500 rpm, basket 20 rpm, 1.0 mm media", "Source": "S28" } ] }, { "caption": "What does automating deburring save on 20,000 pcs/month aluminium housings?", "columns": [ "Item", "Basis", "Value" ], "rows": [ { "Item": "Monthly volume", "Basis": "case input (S2)", "Value": "20,000 pcs" }, { "Item": "Manual cycle", "Basis": "case input (S2)", "Value": "90 s/pc" }, { "Item": "Automated rotary brush cycle", "Basis": "case input (S2)", "Value": "22 s/pc" }, { "Item": "Original monthly machine time", "Basis": "20,000 × 90 s ÷ 3,600", "Value": "500 h" }, { "Item": "New monthly machine time", "Basis": "20,000 × 22 s ÷ 3,600", "Value": "122.2 h" }, { "Item": "Theoretical cycle-time saving", "Basis": "500 − 122.2", "Value": "377.8 h" }, { "Item": "Cycle reduction ratio", "Basis": "(90 − 22) ÷ 90", "Value": "75.6%" }, { "Item": "Defective pcs", "Basis": "20,000 × 3.0% → × 0.2%", "Value": "600 → 40 pcs" }, { "Item": "Reported labour saving / cost change", "Basis": "source-reported (S2)", "Value": "60 h/month; −8%" } ] }, { "caption": "What does cross-hole deburring save on 15,000 pcs/month stainless valve bodies?", "columns": [ "Item", "Basis", "Value" ], "rows": [ { "Item": "Monthly volume", "Basis": "case input (S2)", "Value": "15,000 pcs" }, { "Item": "Manual / new cycle", "Basis": "case input (S2)", "Value": "4.8 / 1.2 min per pc" }, { "Item": "Original monthly time", "Basis": "15,000 × 4.8 min = 72,000 min; ÷ 60", "Value": "1,200 h" }, { "Item": "New monthly time", "Basis": "15,000 × 1.2 min = 18,000 min; ÷ 60", "Value": "300 h" }, { "Item": "Labour time saving (theoretical, full load)", "Basis": "1,200 − 300", "Value": "900 h" }, { "Item": "Caliber note", "Basis": "theoretical machine time vs reported capacity", "Value": "reported +18% includes bottleneck/scheduling — not interconvertible" }, { "Item": "Cycle reduction ratio", "Basis": "(4.8 − 1.2) ÷ 4.8", "Value": "75%" }, { "Item": "Leak-failure pcs", "Basis": "15,000 × 2.6% → × 0.3%", "Value": "390 → 45 pcs" }, { "Item": "Failure reduction", "Basis": "390 − 45", "Value": "345 pcs (−88.5%)" }, { "Item": "Complaints", "Basis": "source-reported (S2)", "Value": "11 → 2 per quarter" } ] }, { "caption": "How do the cross-hole deburring methods compare?", "columns": [ "Method", "Reach mechanism", "Cycle", "Edge control", "Side effect", "Best fit", "Source" ], "rows": [ { "Method": "Flex-Hone", "Reach mechanism": "flexible globes follow the bore to the intersection", "Cycle": "short, CNC-integrable", "Edge control": "plateau finish + radius", "Side effect": "lowest cost; limited on very small or hard burrs", "Best fit": "most general cross-holes", "Source": "S19" }, { "Method": "ECD", "Reach mechanism": "targeted cathode dissolves the burr", "Cycle": "about 20 s, dozens of holes at once", "Edge control": "R 0.05–0.2 mm, ±0.05 mm (single secondary source)", "Side effect": "conductive parts only; workpiece-specific cathode", "Best fit": "hydraulic valve bodies, multi-intersection", "Source": "S6, S21" }, { "Method": "TEM", "Reach mechanism": "gas fills every passage and burns every burr", "Cycle": "< 1 s active, all locations", "Edge control": "edge break 0.02–0.05 mm", "Side effect": "oxide layer; thin-wall risk; not aluminium", "Best fit": "complex hidden intersections, steel/stainless", "Source": "S3, S19" }, { "Method": "AFM", "Reach mechanism": "abrasive media forced through the passages", "Cycle": "3–10 min per batch", "Edge control": "uniform R 0.02–0.05 mm", "Side effect": "slow, high cost, media fixturing", "Best fit": "crisp critical intersections, high-value parts", "Source": "S17, S23" }, { "Method": "HPW", "Reach mechanism": "CNC nozzle aimed into the cross-hole", "Cycle": "seconds per feature", "Edge control": "removes loose burrs", "Side effect": "firm burrs remain; drying needed", "Best fit": "chips + loose burrs, deep/tap holes", "Source": "S24, S19" }, { "Method": "Abrasive micro-blast", "Reach mechanism": "blast nozzle into small bores; reaches holes down to 0.056 in", "Cycle": "manual / automated", "Edge control": "fine blasted texture", "Side effect": "—", "Best fit": "thin brittle burrs", "Source": "S21" } ] } ] }