Sales:
Burlytic Systems
A Technical Products, Inc. Company
50 Pratt’s Junction Road
Sterling, MA 01564
(P): 508-887-1944
Email:
You can also contact us through our web form by clicking here.
What is the Burlytic® Systems deburring process?
How important is fixturing to the process?
Is the electrolyte safe and do I need special venting for the system?
How long does it take to process a part in the Burlytic® Systems process?
How often is the electrolyte replaced?
What maintenance does the system require?
Why does the process remove burrs and not affect the part itself?
Does the process have dimensional control?
What are the environmental concerns for waste disposal?
How many parts can be processed in a given batch?
Can a system be customized for my particular manufacturing operation or part?
How is metal removed electrochemically?
Is the cycle time material dependent?
What materials are the `cathodes` made from?
What is the life of a `cathode`?
Do I need a special-shaped `anode contact` developed for every different part feature?
What materials are the `anode contacts` made from?
What is the life of an `anode contact`?
What happens if a burr (anodic + charge) contacts the `cathode` (- charge)
What protection devices are offered to avoid short circuit tooling damage?
What is the typical gap between workpiece (burred edge) and cathode?
What would a typical fixture cost?
Should customers be encouraged to make their own tooling/fixtures?
How critical is electrolyte flow?
What happens to the burrs? Are they burned up? Are they dissolved?
How does the process/machine know when the burr is gone or if the edge is sufficiently radiused?
What is the largest burr you can remove?
How do we decide if rough mechanical pre-deburring is required?
Are there any part size limitations
Are there any material limitations? Materials more ideal than others?
Are other features/surfaces, nearby to the edges being deburred, adversely or positively affected?
What kind of finish can we expect from Burlytic® Polishing? Give examples.
Will a parts exposure to the Burlytic® process affect its hardness?
Is part hardness a factor in process speed, surface finish, and other results?
Will the Burlytic® process induce, remove, or otherwise impact part stress?
Will the Burlytic® process remove a recast layer?
How important is part surface cleanliness to the process results?
How important is electrolyte cleanliness to the process results?
What is considered normal operating temperature?
How important is it to maintain electrolyte temperature?
Does the electrolyte require routine replacement?
What are the types of electrolytes available?
Is this process expensive to operate? What are the cost considerations?
Are there any operator health or safety hazards to be aware of?
Does the machine operator require training?
What is the expected life of a Burlytic® machine?
What size equipment would I need for my part’s application?
Does TP Manufacturing provide contract deburring services?
What is the Burlytic® Systems deburring process?
The Burlytic® Systems deburring process is an electrochemical deburring and finishing process for use on most hardened and non-hardened metals. Voltage, in combination with patented Burlyte® electrolyte, and the cathodes placed in the tank or set upon the bench top, causes most of the metal removal on the part to take place at the edges, rather than equally across the surface. All parts need to be fixtured in this process so as to be able to make electrical contact with the part and to hold it.
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How important is fixturing to the process?
It is critical to the process. The fixturing is designed to effect the optimal metal removal or surface finish on those areas of the part specified. It may mask areas not to be touched, which may have critical tolerances or desired finishes on key attributes already completed. Fixture design, development and fabrication ensure that the customer`s requirements will be met each and every time their parts are processed. Multiple parts may be processed on the same fixture.
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Is the electrolyte safe and do I need special venting for the system?
The electrolyte is based on ethylene glycol and is safe to handle. It does not deplete, fume or cause damage to adjoining equipment as do traditional ECD equipment using salt-based electrolytes. It’s workplace friendly. It`s slippery to the touch, doesn`t burn holes in your skin, clothing or anything else for that matter. It easily washes off with water. The process requires no special workplace safeguards: no special containment, no rubber suits for the operators, typically no venting or any other physical requirements to render its operation safe. We do recommend safety glasses and gloves as a practical consideration.
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How long does it take to process a part in the Burlytic® Systems process?
The average process time falls within a range of 30-90 seconds. There are parts which may require several minutes, and others that require only 1 second. Multiple parts processed at the same time will often require a slightly longer cycle time than if only one of the parts were processed.
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How often is the electrolyte replaced?
Rarely, if ever. The electrolyte does not deplete with use. It is continually filtered to remove the hydroxides created through the metal removal. There is loss of electrolyte through drag out, when the parts are removed from the process and rinsed off however, this is minimal. Unless the electrolyte is heavily contaminated, it will not need to be replaced.
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What maintenance does the system require?
The filters need to be changed, depending on use and throughput. In a typical high production environment, filters are changed every 2-3 weeks. The pH and conductivity levels of the electrolyte need to be monitored daily, and occasionally, should the pH go above 7a small amount of Nitric acid is necessary to bring the pH back in balance. Sometimes in an especially humid environment the conductivity level rises with the amount of water absorbed into the electrolyte from the atmosphere. Dewatering would then be required to bring the conductivity level back into balance. (Dewatering units are available as optional equipment.)
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Step 1: Attach a clean, dry part to a holding fixture.
Step 2: Immerse the fixture in the electrolyte solution attaching the fixture to the anode (+) bar above the electrolyte surface.
Step 3: Push the start button. This applies a preset-voltage, electrical pulse train and specified time.
Step 4: Disconnect the fixture from the anode bar and remove from the bath.
Step 5: Remove parts from fixture, and then rinse with water and dry.
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Why does the process remove burrs and not affect the part itself?
It is a well known phenomenon that electric fields will concentrate at sharp points. This principal is at work with the common lightening rod. When we apply a voltage to the high resistance electrolyte, the current will be focused into the highest concentration of the electrical field which will typically be at the burrs. The burrs are released in the form of hydroxides, which are insoluble in the electrolyte. They can be mechanically filtered from the solution.
The process is selective but not infinitely so. High points on the surface of a part may also be affected as these represent microscopic burrs on the surface. The burr removal here usually results in a smoother finish on the part.
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Yes, highly repeatable. The electrolyte is non-wearing, and the process relies on highly repeatable electrical pulses from a switching type power supply used in the most sophisticated plating applications. These power supplies are highly reliable. Other factors that require control include temperature (maintained with a chiller), cycle time and current pulsing (controlled by a programmable logic controller).
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Does the process have dimensional control?
Yes. Metal removal follows Faraday`s Law of electrolysis where the metal removed in an electrolytic cell is function of time and current. If it is desirable to remove more material or create large edge radii, one merely needs to add to the cycle time. Time can be added incrementally. So an under-processed part can be reprocessed by adding the necessary time without adverse effects. It would be as if the part was processed one time for the total cycle time required.
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What are the environmental concerns for waste disposal?
The electrolyte does not wear out so it does not require disposal. However, there are filters that will require periodic replacement. These filters will contain electrolyte and ions of the metals of which the parts are made, and these would be considered hazardous. Therefore, it is recommended that the filters be drummed for disposal by a reputable hazardous waste removal company. A typical operation may produce one drum of filters annually.
The other waste issue is rinse water. After rinsing, the water is contaminated. The lowest cost solution is to install an atmospheric or vacuum evaporator. In this way, you may recycle the rinse water, and the contaminate residue can be drummed with the filters. Again, the volume of waste is normally quite small.
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How many parts can be processed in a given batch?
The answer depends on the size of the part and the power and cooling capacity of the machine you select. For example, deburring a quarter inch cutting tool with a fluted length of one inch will draw about 5 amps. Therefore, with a Model 60 (60 amp capacity) system, it should be possible to process as many as twelve parts in one operating cycle. Machines are available to 500 amp capacity, and beyond.
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Can a system be customized for my particular manufacturing operation or part?
Absolutely. While we offer a line of standard machines, systems can also be designed to operate in virtually any type of production line or work cell and that can run in manual, semiautomatic or automatic mode. Custom systems have been built for a variety of application requirements ranging from a simple reconfigured processing tank to an in-line, reel to reel stamping line. Almost anything is possible.
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How is metal removed electrochemically?
The fundamental principle underlying the Burlytic® Process is not new. Also known as “reverse electroplating” this process has been used for a long time. Deburring and polishing occur when the workpiece is submerged in a conductive bath of Burlyte® Electrolyte and DC electric current is passed between the workpiece and a set of in-tank cathode screens. A cathode is simply a metal electrode of opposite polarity to the part. The part is always positive (+) and cathodes are always negative (-).
As electrical current passes through the part and electrolyte, an electro-chemical process takes place at the part surface. The electrical current concentrates at points (the burrs) and along the part edges (see graphic). This effect causes metal to be selectively dissolved at the burred edges thus effectively removing the burrs and leaving the surfaces of the part mostly unaffected. The edges become slightly radiused.
While the amount of material removed from the workpiece is primarily a function of current and time, more deburring action occurs if the cathodes are placed closer to the edges but one of the many advantages of the Burlytic® system is that the cathodes can be placed at a distance. In many instances, the process deburrs without any locally placed cathodes; just submerge the part and run it. The process becomes essentially “self-tooling”.
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Most parts that we’ve sampled for customers are deburred in 30 to 90 seconds. However, this cycle time is largely dependent on your part characteristics including part size, number of burrs, part material, etc. For more information, go to our page entitled Common Metals.
Polishing is typically accomplished in 1 to 5 minutes.
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Is the cycle time material dependent?
As with all ECD processes, each metal has its own processing characteristics. Some metals require inhibiting, some don’t, some will polish, some will granulate, some work very slowly, some very quickly and some won’t process at all.
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While conformal shaped tooling is an absolute requirement of Sodium Nitrate and Sodium Chloride-based ECD processes, it is largely not required with the Burlytic® process (ref. figures below). The combination of our patented Burlyte® electrolyte (with higher electrical resistance) and pulsed current technology produce a “peak effect” which causes selective dissolution of burrs and sharp edges without special tooling.
Burlytic® electrode must only be in the general area of the burr. The burr is dissolved from the tip of the burr to the root in a controlled manner. Deburring field is self-focusing.
ECD electrode must be close fitting and conformal to the workpiece edge. Spacing must be carefully controlled. Burr is dissolved at the root as a function of tool position accuracy.
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What materials are the `cathodes` made from?
Typically brass and stainless steel. Copper is another suitable choice.
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What is the life of a `cathode`?
Cathode life should prove indefinite unless subjected to continued short circuits or mishandling.
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Do I need a special-shaped `anode contact` developed for every different part feature?
Typically no. But some geometry’s may require a special shape.
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What materials are the `anode contacts` made from?
Anode contacts used with the Burlytic® process typically include copper, copper-tungsten, stainless steel, zirconium shaft with platinum tip, or over-molded copper-platinum. While exotic metals such as Tantalum and Niobium may also be used, choosing the right material is a balance between contact performance, contact maintenance and cost of the base contact metal.
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What is the life of an `anode contact`?
Anode life is largely dependent on the contact material. Consider copper or copper-tungsten anode contacts which are the least expensive but require the highest maintenance. Theses contacts should last for thousands of cycles so long as they are maintained in a dry condition. Higher end materials such as copper-platinum and Tantalum and Niobium anodes will last much longer with less maintenance but of course the material is more expensive.
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What happens if a burr (anodic + charge) contacts the `cathode` (- charge)
This is called a short circuit and the Burlytic® System is self protecting against this event. If the current drawn exceeds the maximum current allowed by the process, the supply will drop the voltage back to prevent excess current. As each cycle is started, the system will also check the process for a short circuit before applying process power. If a short circuit exists, it will interrupt the power supply until the contact situation is rectified.
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What protection devices are offered to avoid short circuit tooling damage?
All Burlytic® Deburring System equipment models come standard with short circuit protection.
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What is the typical gap between workpiece (burred edge) and cathode?
The typical gap ranges anywhere from fractions of an inch to whole inches. Having stated that the closer the cathode is to the material the more aggressive the metal removal. Keep in mind that no conforming electrode geometries are required compared to conventional ECD processes.
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What would a typical fixture cost?
Prices can range from $100`s to $1,000`s depending on part complexity and number of parts per fixture.
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Should customers be encouraged to make their own tooling/fixtures?
Over time with the right training and experience, you should be able to make your own tooling. Until that time, it is best that we design and build your tooling. We can also design the tooling and send the drawings to you so you can use your own machine shop.
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How critical is electrolyte flow?
Electrolyte flow is very important in that it evacuates the immediate area around the parts being deburred from hydroxides and metal ions. Having fresh electrolyte flowing around the part promotes optimal current distribution and thus, process consistency. Each Burlytic® System is equipped with a sparger installed on the floor of the tank. It provides a steady flow of electrolyte to keep the entire contents of the tank in constant circulation. The rear section of the tank includes an electrolyte conditioning area. In this area the electrolyte is filtered, degassed, and cooled.
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What happens to the burrs? Are they burned up? Are they dissolved?
As electrical current passes through the part and electrolyte, an electro-chemical process takes place at the part surface. The electrical current concentrates at points (the burrs) and along the part edges. This effect causes metal to be selectively dissolved into harmless metal hydroxides at the burred edges thus effectively removing the burrs and leaving the surfaces of the part mostly unaffected. The edges may become slightly radiused.
As burrs are dissolved, metal ions are released into the Burlyte® bath and continuously filtered. Click here to view “What are the environmental concerns for waste disposal?”
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How does the process/machine know when the burr is gone or if the edge is sufficiently radiused?
The amount of material removed from the workpiece is primarily a function of electrical current and time as well as the position and location of the cathode to the workpiece. Each part will have these process parameters identified for optimal burr removal. As long as the equipment is maintained and process parameters adhered to, burr removal will be extremely repeatable. However, should burr sizes vary widely from batch to batch, the process parameters can easily be tweaked to accommodate that variation.
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What is the largest burr you can remove?
Nominally up to .040`”, but burrs twice this size can also be removed.
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How do we decide if rough mechanical pre-deburring is required?
Burrs larger than .040” should be removed prior to the Burlytic® process. Typical examples of such burrs include drill caps, hangnail burrs and rolled burrs. Click here to go to Deburring Nomenclature. Loose burrs lodged internally should be shaken out or flushed away.
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Are there any part size limitations
There is no theoretical limit to the size of the process tank. A tank which would accept a piece 100 feet long will process in much the same manner as a piece 1 inch long. The only difference is scale. If you can comfortably get the piece into the processing tank and properly submerged in the electrolyte, and adequate power and cooling are provided, you can process it.
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Are there any material limitations? Materials more ideal than others?
Each metal has its own processing characteristics. Some metals require inhibiting, some don’t, some will polish, some will granulate, some work very slowly, some very quickly and some won’t process at all. To view a cursory list of common metals and their processing speed characteristics, please go to Common Metals.
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Are other features/surfaces, nearby to the edges being deburred, adversely or positively affected?
All ECD processes can, under the right conditions, produce a condition called ‘smut’. Smut is generally caused by electrophoresis which is the migration of removed metal back to low current density areas of the part (inside corners, for instance).
There are several reasons why smut may appear on parts being deburred but there are many remedies to reduce or even eliminate smut altogether.
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What kind of finish can we expect from Burlytic® Polishing? Give examples.
Depending on the part’s metallurgy, method of manufacture, grain structure, etc., the Burlytic® process typically imparts impressive and desirable surface finishes. With stainless steel for example, a surface finish better than 16 Ra is not uncommon.
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Will a parts exposure to the Burlytic® process affect its hardness?
The Burlytic® process is a cold process and therefore does not affect a part’s hardness.
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Is part hardness a factor in process speed, surface finish, and other results?
On rare occasion, Burlytic® process attributes have been affected by certain hardened parts. It is desired that we are made aware of any hardness specifications prior to running any samples.
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Will the Burlytic® process induce, remove, or otherwise impact part stress?
The Burlytic® process will not impart any stress to part, although it may lessen or eliminate desirable stresses.
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Will the Burlytic® process remove a recast layer?
Recast is a thick layer of slag or re-solidified metal that poorly adheres to the surface after EDM machining or laser cutting. Recast is not a burr in the technical sense but can cause similar problems. Removing recast improves fatigue strength.
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How important is part surface cleanliness to the process results?
The presence of oils, greases and to some extent water soluble cutting fluids on the part will inhibit the electrical conductivity between the it and the cathode. Therefore it is recommended that parts be cleaned before processing. TP Manufacturing offers various choices of parts cleaners including ultrasonic cleaners.
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How important is electrolyte cleanliness to the process results?
During processing, the dissolved burrs turn into metal hydroxides, some of which will get suspended in the electrolyte while others will accumulate at the bottom of the tank. Those hydroxides in suspension get filtered out. Running the electrolyte “dirty” does not seem to adversely affect its operation, but, of course, hydroxides should not be allowed to accumulate indefinitely. So in essence the electrolyte never “goes bad” even if it is never cleaned.
Unless the electrolyte is grossly contaminated with a foreign substance, it should never need replacement. As parts are removed from the electrolyte, however, a small amount of electrolyte will be dragged out of the tank along with the part. These repeated small amounts will eventually need to be replaced.
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During processing, metal is dissolved from the part and is turned into suspended hydroxide particles. These particles are collected by an efficient cartridge filtration system located on the suction end of the filter pump, located in the electrolyte conditioning tank behind the main process tank. As the filter fills with hydroxides, the sludge will accumulate to approximately ½” thick. This is your indication that it is time to change the filter elements.
Although considered low level, the hydroxide sludge from deburring aluminum, stainless steel or iron parts is still considered toxic waste by definition. In the worst case, such material is carted away as an industrial waste by a licensed hazardous waste disposal agency. A high volume operation may produce one drum of filters annually.
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What is considered normal operating temperature?
Since the electrolyte is resistive, the bath will heat up when current is passed through it. The chiller keeps the bath at an ideal temperature of 59ºF by way of a heat exchanger located outside the tank.
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How important is it to maintain electrolyte temperature?
As the process runs, heat is generated by current flow through the electrolyte and mechanical energy caused by the internal pump. If this heat is not removed, the electrolyte temperature will move out of the proper operating range thus upsetting electrical current control and surface finish. Hot electrolyte will prevent polishing and may encourage black stains to form on a part. It is best to maintain the temperature within 2°F to 5°F.
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Does the electrolyte require routine replacement?
Unless the electrolyte is grossly contaminated with a foreign substance, it should never need replacement. As parts are removed from the electrolyte, however, a small amount of electrolyte will be dragged out of the tank along with the part. These repeated small amounts will eventually need to be replaced.
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What are the types of electrolytes available?
Burlyte® electrolytes are provided in two types: “A” and “C”. The “A” electrolyte is compounded for processing all metals except copper and copper alloys. The “C” type is used for copper and its alloys. The “C” type can be used for all metals, but requires a longer processing time than type “A” electrolyte.
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The computer controlled power supply of the Burlytic® System converts factory-supplied power from AC to DC. It further reduces the voltage between 24 and 48 VDC, the range in which most metals can be deburred in the Burlytic® process.
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Is this process expensive to operate? What are the cost considerations?
Not counting labor, operational costs are estimated between $6 to $10 per hour depending on the machine usage and capacity. This includes make-up electrolyte, electricity, waste disposal, water and maintenance.
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Are there any operator health or safety hazards to be aware of?
The following hazards are inherent with any ECD process:
Electrical – The National Electrical Code permits exposed conductors up to a threshold of 50 VDC. The Burlytic® System operates below this threshold.
Hydrogen gas – All Electrochemical systems produce hydrogen when running. The Burlytic System generates very small amounts of this gas but not enough to create a hazardous condition. This gas can, however, if allowed to accumulate in cup or domed shaped parts or shrouded components of the system, create a hazardous condition.
High Current – Low voltage with high current is applied across the anode and cathode buss bars of this equipment when running. Be careful not to short-circuit these two bars with jewelry, tools, parts or other metallic objects. Momentary skin contact across the bars is not normally hazardous but metallic contact will promptly heat the metal and will burn exposed skin.
Safety Glasses – The electrolyte, while not hazardous under normal conditions, should not be exposed to skin for long periods nor ingested. We recommend appropriate personal protective equipment such as safety glasses to keep splashed electrolyte out of the eyes and gloves for extended periods of handling.
Short Circuits – Accidental short circuits, particularly those occurring above the electrolyte level, can cause molten metal to splatter into the operator’s face. We recommend that the operator wear safety glasses while running the process.
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Does the machine operator require training?
Yes. TP Manufacturing will provide formal on-site training to our client’s workforce upon purchase and receipt of their Burlytic® System. At the client’s request, this training can also take place at our factory. Training is typically accomplished in a few hours. Of course our sales and engineering staff will also be pleased to handle any technical questions you may have after the formal training. Simply give us a call.
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What is the expected life of a Burlytic® machine?
Ten plus years.
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What size equipment would I need for my part’s application?
The answer depends on the size of the part and your production rate. For example, deburring a quarter inch cutting tool with a fluted length of one inch will draw about 5 amps. Therefore, with a Model 60 (60 amp capacity) system, it should be possible to process as many as twelve parts in one operating cycle. Machines are also available in 100 amp, 250 amp and 500 amp capacity. As the saying goes, “You do the math!”
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Does TP Manufacturing provide contract deburring services?
TP Manufacturing designs, fabricates and markets deburring systems that utilizes this unique technology. Contract deburring services using the Burlytic Systems technology are provided by Electroburr, LTD. in Wellington, OH. Visit them at www.electroburr.com.
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