8 advantages of electropolishing for deburring metal parts
Able Electropolishing is the world's largest electropolishing specialist, with over seven decades of experience, innovation and collaboration with manufacturers working in some of the world's most challenging industries, including aerospace, medical and more. In this article, the experts at Able describe the eight key benefits of electropolishing for removing microburrs from metal parts.
Stamping and machining can leave behind a variety of surface imperfections that affect the fit, form and safety of metal parts. One of the most common is burrs.
Microburrs that are created at the corners or edges of parts during blanking, milling, broaching, lapping or grinding can become dislodged during assembly or use and contaminate or damage the materials or components they come into contact with.
It's no small concern for metal parts used in any number of sensitive places, like food or pharmaceutical production equipment, or fuel lines and gear assemblies. Burrs that become dislodged near moving parts can lead to mechanical failure or worse.
Burrs can also create galling that causes screws or fasteners to seize up or fail to form a proper seal or connection with another part.
This is why deburring is a key part of the finishing process for metal parts for a wide range of industries.
While less precise methods of finishing, like tumbling, vibra-finishing or hand deburring, may be effective in some cases, none can match electropolishing for its ability to achieve the highest-quality surface finish with microscopically precise results. This is why electropolishing is frequently specified for flight-critical metal parts and parts used in medical devices, surgical instruments and implants.
How Electropolishing Works
Electropolishing has been used for commercial applications since the early 1950s and has evolved to become the metal finishing process of choice for parts subject to the highest standards for surface finish. It works by subjecting parts to an electrically charged chemical bath that removes metal ions from a part's surface with microscopic precision, leaving behind a smooth and bright surface.
VIDEO: Able Electropolishing Advantage
At Able Electropolishing, over seven decades of collaboration with our clients have driven the evolution and customization of a process that can achieve the highest quality results for critical metal parts.
Electropolishing vs. Other Finishing Methods for Burr Removal
Fragile or intricate metal parts, like those used for medical devices, surgical instruments, and implants, are not well suited to finishing processes like mechanical or vibratory polishing, which can damage fragile parts or create inconsistent results for parts with complex shapes. Passivation, which can remove free iron, contaminants and foreign particles left behind by machining processes, does not remove any surface material, and is not effective for burr removal.
Because electropolished parts are mounted in racks customized for each part, the process can accommodate small and large parts and is particularly well suited for the most fragile parts.
Microfinishing
OEMs and contract manufacturers are constantly faced with the challenge of improving their product from a metal finishing perspective based on varying requirements.
Able works with clients to establish processing parameters for each part, determining proper material removal/processing time and fixturing. In addition, we ensure that the process supports production requirements at scale -- an often-overlooked consideration that contributes to damaged parts. Able has the ability to develop custom solutions in conjunction with our clients to maintain the integrity of each lot shipped.
Electropolishing provides the flexibility of highly targeted material removal to meet the most demanding tolerances. In the prototype stage, it is important to test the processing requirements and provide an iterative process with feedback from both the client and our engineering team working together.
With electropolishing, stock removal can vary based on part-by-part requirements and surface improvement can differ based on the material type and the amount of material removed. There is no surface improvement beyond .001" material removal but in some cases, more may be removed for sizing purposes. In addition, material removal is measured by the combined total per surface.
Precise, Uniform and Consistent Results
Successful deburring for critical metal parts is contingent upon the ability to remove a precise layer of surface material.
No other process can match electropolishing for its ability to achieve results with removal tolerances of +/-.0002". Similar to lightning striking the high points, electropolishing delivers higher current density on the high points or edges which makes it ideal for micro-deburring.
The customized nature of the electropolishing process, from racking to chemical formulation to timing, would be of little value if it could not be reproduced consistently. But unlike other finishing processes, electropolishing is prized for its consistent results. The addition of robotic automation takes consistency to another level.
Burr Removal with Additional Benefits
Electropolishing does far more than eliminate burrs. Electropolishing creates metal parts that are pristine and free of surface defects and contaminants, eliminating the need for additional cleaning processes or treatments. The result is parts that are more durable and resistant to corrosion and premature failure. This is high on the list of reasons that aerospace manufacturers specify electropolishing as the last step in the manufacturing process for flight critical metal parts.
Here's a list of the advantages of electropolishing:
- Microscopically precise removal of surface material of ±.0002"
- Customized racking to accommodate fragile and complex parts small and large
- Leaves parts with enhanced durability and cycle life
- Creation of a pathogen-resistant surface
- Superior cleanability
- Ultraclean finish
- Decorative finish
- One stop process for cleaning and removing surface defects
Conclusion
Deburring is a critical step in the finishing process for many metal parts. Electropolishing is the most precise and effective process for removing microburrs -- enabling the removal of a precise and consistent amount of surface material within the tightest tolerances.
Customized racking and chemical baths ensure the highest quality finish for each part, with a multitude of additional benefits and no need for secondary cleaning processes.
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