At Weiler Abrasives, we manufacture an extensive selection of wire and nylon deburring brushes. Wire brushes and nylon abrasive brushes have been employed successfully for many years as cost-effective solutions for a wide variety of deburring applications. Their ability to quickly remove burrs without changing part dimensions has been understood for decades. In recent years, these products have seen increased implementation in automated deburring environments.
We know every step of the metalworking process and understand the impact burrs and sharp edges have on the finished product. Our deburring brushes in both wheel and disc configurations help complete this critical step in the finishing process with speed and efficiency. Whether for edge deburring, surface finishing, bore deburring or edge radiusing, Weiler has solutions to help remove burrs from parts in the most complex applications.
Modern metalworking is more precise and has more efficient use of material than ever before, but burr removal remains a common and critical part of the process. At Weiler Abrasives, we have extensive experience with burrs common to steel, high performance alloys, and aluminum. Based on our expertise, we developed a qualitative burr measurement system to determine the correct deburring brushes for automated process use. Our system classifies burrs as:
We manufacture hundreds of products for deburring applications using wire and our Nylox® nylon abrasive filaments. With Nylox brushes, the choice to run wet or dry depends on the application. Deburring brushes made from wire and Nylox each offer distinct advantages for deburring:
Wire brushing is driven by impact, meaning these brushes work at high RPMs. In wire brushing, the wire tips do the work. Since the tips of the wires (not the sides) are the primary working elements of a wire brush, increasing the load (pressure applied) does not increase aggression but instead causes premature wire fatigue. In addition to increasing surface speed, users can also enhance wire brush aggression by increasing wire point density and filament stiffness (diameter).
Because wire brushes deburr through an impact-driven process, they remove burrs very quickly. With optimal operating parameters, they can thoroughly deburr an edge in a few seconds. Dwell times beyond a few seconds are unlikely to produce improved results.
Nylox nylon abrasive filament brushes are best understood by thinking of each brush as a collection of flexible files. Each filament is co-extruded with abrasive grains which act like teeth on a file.
Because Nylox brushes perform deburring primarily by wiping and filing rather than impact, dwell time is a critical variable affecting their performance. The burred edge must be exposed to the brush for sufficient time for the filaments to remove the burr through abrasion. Brush RPM is also critical. Higher RPMs prevent the sides of the brush filaments from smoothly wiping across the part edge and often reduce the effectiveness of the brushes.
A wide variety of abrasive nylon fill materials are available, and each offers different performance characteristics. These filaments may contain abrasives such as aluminum oxide, silicon carbide, ceramic and diamond for special applications.
The flexible nature of the Nylox brushes causes the cutting action to be "edge selective." Since the filaments deflect away from a broad surface and absorb a large portion of the applied load, Nylox brushes tend not to alter the overall dimensions and geometry of a part.
There are four general applications in brush deburring. Depending on the product geometry and the size and location of the burrs, products may require one or more deburring applications to achieve complete removal. The four different deburring applications are:
In any deburring process, deburring brushes need to be chosen with parameters that fit particular criteria. The right deburring brushes will deliver optimal results in the least amount of time, improving production cycle times and the quality of the finished product. Four types exist, and we have multiple options for them all, including: