XEBEC Brush™ Surface Process conditions

Processing conditions

 Set the processing conditions depending on the purpose: deburring or cutter mark removal and polishing.

Deburring

Set the following 5 conditions.

(1) Rotation speed
(2) Depth of cut
(3) Feed rate
(4) Brush projected (the length of the brush projected from the sleeve)
(5) Direction of brush rotation
 

Rotation direction

Rotational direction of the brush has a significant impact on the deburring capability.

For burrs in horizontal direction (i.e. side burr) generated after milling, the machining must be done by up cutting whereby the brush pushes upward against the burrs from the bottom.
When down cutting, there is a possibility that the burrs may not be removed properly because the burrs being bent and stuck to the surface.
 
For vertical burrs (i.e. top burrs), there is no significant difference by rotation direction.
 
 

Initial processing conditions

Set the initial conditions according to burr direction (top burr or side burr) and burr size (root thickness burr).
Product code Depth of cut D Rotation speed S
(min-1)
Feed rate F
(mm/min)
Brush projection
(mm)
Vertical
burrs
Horizontal
burrs
Recommended
rotation speed
Maximum
rotation speed
Burr root
thickness
0.05mm
Burr root
thickness
0.1mm
A13-CB06M 0.5 0.5 8,000 (MAX10,000) 4,000 2,500 10
A13-CB15M 1.0 1.0 4,800 (MAX6,000) 4,000 2,500 10
A11-CB06M 0.5 0.5 8,000 (MAX10,000) 4,000 2,500 10
A21-CB06M
A31-CB06M
A11-CB15M 0.5 1.0 4,800 (MAX6,000) 4,000 2,500 10
A21-CB15M
A31-CB15M
A11-CB25M 0.5 1.0 4,000 (MAX5,000) 4,000 2,500 15
A21-CB25M
A31-CB25M
A11-CB40M 0.5 1.0 2,400 (MAX3,000) 4,000 2,500 15
A21-CB40M
A31-CB40M
A11-CB60M 0.5 1.0 1,600 (MAX2,000) 4,000 2,500 15
A21-CB60M
A31-CB60M
A11-CB100M 0.5 1.0 960 (MAX1,200) 4,000 2,500 15
A21-CB100M
A31-CB100M

If burrs remain

Increase the rotation speed to the upper limit.
If burrs still remain, then decrease the feed rate.
 
If the workpiece cannot be deburred even by the 2 above-mentioned procedures, the machining condition may be incorrect or the burr size is too large.
Change the brush with higher grinding power. The grinding power of the brush is in the order of : Red < White < Blue.
 

To extend tool life/If the edge is too rounded

Decrease the rotation speed in increments of 1,000min-1.
If tool life or edge quality is still not improved, the machining conditions or the brush color may not be appropriate.
The grinding power of the brush is in the order of the following colors: Red < White < Blue.

Cutter mark removal and polishing

Set the following 4 conditions.
 
(1) Rotation speed
(2) Depth of cut 
(3) Feed rate
(4) Brush projection (the length of the brush projected from the sleeve)
 

Initial processing conditions

Product code Depth of cut D (mm) Rotation speed S (min-1) Feed rate F (mm/min) Brush projection (mm)
Recommended  Maximum Recommended Feed rate
A13-CB06M 0.1~0.5 8,000 (MAX10,000) 300 10
A13-CB15M 0.1~0.5 4,800 (MAX6,000) 300 10
A11-CB06M 0.1~0.5 8,000 (MAX10,000) 300 10
A21-CB06M
A31-CB06M
A11-CB15M 0.1~0.5 4,800 (MAX6,000) 300 10
A21-CB15M
A31-CB15M
A11-CB25M 0.1~0.5 4,000 (MAX5,000) 300 15
A21-CB25M
A31-CB25M
A11-CB40M 0.1~0.5 2,400 (MAX3,000) 300 15
A21-CB40M
A31-CB40M
A11-CB60M 0.1~0.5 1,600 (MAX2,000) 300 15
A21-CB60M
A31-CB60M
A11-CB100M 0.1~0.5 960 (MAX1,200) 300 15
A21-CB100M
A31-CB100M

If cutter mark is not removed or polished

Increase the rotation speed to the upper limit.
If this does not work, then increase the number of passes.
 
FInish quality may be improved by increasing the number of passes at high feed rate instead of decreasing the feed rate.
Example:
○Feed rate 1,000mm/min x 3 passes
△Feed rate 300mm/min x 1 pass 

If the surface becomes rough

The brush color may not be appropriate.
The surface smoothness of the brush is in order of Red > White > Blue.

Brush color

If the grinding power is not sufficient, you can change the brush to the one with higher grinding power. 
If the grinding power is excessive, you can change the brush to the one with lower grinding power. 
The grinding power of the brush is in order of Red < White < Blue.  

Tips for polishing

To improve surface smoothness in a short time, it is recommended to use a blue brush first for rough and medium polishing and then change to a red brush for finishing.
 
Please see the case studies of actual machining from the links below.

CNC mold polishing (stainless steel)
 
CNC mold polishing (NAK)
 
CNC mold polishing (SKD)

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