Optimizing Edge Rounding on Laser-Cut Sheet Metal Using the DM1100 C

 The DM1100C Edge Rounding Machine was recently tested to achieve an edge rounding radius of 0.3-0.5mm on stainless steel parts for a customer specializing in precision sheet metal fabrication and enclosures, particularly for laser-cut components that require precise edge rounding for improved handling and coating adhesion. The primary requirement was to obtain a uniform edge rounding while maintaining the integrity of the parts, which typically do not have burrs, making a Deburring Contact Roller or abrasive belt station unnecessary. Due to the high precision of modern fiber laser-cutting machines, burr formation is minimal, eliminating the need for additional heavy-duty deburring processes, as the laser-cut edges are already clean and sharp, requiring only edge rounding to ensure smoothness.

Testing Parameters and Process

The customer specializes in high-precision laser cutting and sheet metal processing, producing components for industries such as electronics, industrial equipment, and mechanical assemblies. Their operations require smooth edge rounding to ensure compatibility with downstream processes like bending, welding, and assembly., requiring precise edge rounding to improve handling and surface treatment results. Ensuring smooth and uniform edges is crucial for avoiding sharp edges in assembly processes and enhancing coating adhesion.

The samples were categorized into two groups:

1. Samples A to D: Maintained the same process conditions while varying pressure and speed.
2. Samples E, F, and G: Also followed a standardized set of conditions, focusing on different material interactions.~

Sample A after tests

Sample G after tests

To optimize edge rounding on laser-cut precision components used in enclosures, brackets, and structural elements, two different crossbelt consumable types were tested:

• Green Flex: A flexible mix of 40/60G abrasive + green fleece, designed for a more controlled material removal and edge rounding process.
• Violet Plus: A 3-row cut design with 60G ceramic + purple fleece, known for its efficiency in edge rounding applications.

Green Flex Block

Violet Plus Block

The tests were conducted at speeds between 1 m/min and 3.2 m/min to evaluate the impact of different throughput speeds on edge rounding efficiency.

Results and Best Performances

From the test results, samples B and F produced the most consistent and high-quality edge rounding:

• Sample B (Green Flex): The reduced feed speed combined with increased pressure resulted in superior edge rounding, surpassing previous tests in uniformity and smoothness.
• Sample F (Violet Plus): With one pass and a lower feed speed than the previous sample, this test provided the best overall combination of edge rounding and surface quality.

Sample B: edge rounding detail

Sample F: edge rounding detail

Choice of Consumables: Why Violet Plus?

When processing thicker parts, Green Flex is ideal as it allows for higher pressure applications, such as 3.7mm of pressure, effectively reaching below the surface without affecting the integrity of the part.

For thinner parts (2mm thickness), applying excessive pressure (e.g., 1.5mm) could risk contact with the conveyor belt, potentially damaging it and leading to a suboptimal rounding result.

By utilizing Violet Plus, which contains harder abrasives, we were able to reduce the pressure to just 0.5mm while still achieving a similar edge rounding effect to that of Green Flex.\

Throughput Speed Selection: Why 1 m/min?

• We tested speeds between 1 m/min and 3.2 m/min to determine the best balance between efficiency and edge rounding quality.
• Higher speeds resulted in less uniform rounding, leading to inconsistent edges.
• 1 m/min provided the most uniform and consistent rounding, ensuring a smooth and controlled finish.

The DM1100C Edge Rounding Machine successfully delivered a 0.3-0.5mm edge rounding with a high degree of consistency, meeting the customer’s expectations for laser-cut sheet metal components that require precise edge refinement for handling and further processing. However, the DM1100 C only features top crossbelt processing, meaning edge rounding is applied from above, but not on the underside of the part.

For an optimized and more efficient solution, the DM1600 2C EVO is recommended. This model features two crossbelt stations, allowing for simultaneous top and bottom edge rounding, ensuring a fully uniform finish on both surfaces. With a wider 1600mm working capacity, it can handle larger parts while maintaining the same precision and efficiency.

This edge rounding system is particularly effective for manufacturing applications, where sharp edges must be smoothed to meet functional and aesthetic requirements in industries such as aerospace, medical technology, and custom metal fabrication., ensuring optimal surface preparation for powder coating, anodizing, and other protective coatings, improving adhesion and corrosion resistance. Many industries, including precision sheet metal fabrication, electronics enclosures, and industrial equipment manufacturers, rely on crossbelt edge rounding technology to achieve high-quality radiused edges, essential for safe handling, improved assembly fit, and superior coating performance.

These results confirm the effectiveness of the DM1100 C in post-laser-cut processing, ensuring consistent edge preparation for parts used in automated assembly lines, robotic welding systems, and precision-fitted mechanical structures., particularly for laser-cut sheet metal parts that require precise finishing for improved safety, assembly efficiency, and coating performance. However, the DM1600 2C EVO is the ideal solution for customers requiring double-sided edge rounding, offering top and bottom processing for increased productivity and uniformity.

If you want to know more about this test, visit our contact page on the website https://nsmaquinas.com/contacts/ or send us an email directly to marketing@nsmaquinas.pt.

Edge Rounding Precision with C machines - up to 1100mm and 1600mm

When it comes to achieving flawlessly rounded edges for your laser parts and small components, the DM1100 C and DM1600 C edge rounding machines are your ultimate solution. These machines are meticulously designed with user-friendliness and efficiency in mind, ensuring a hassle-free process that consistently delivers impeccable results.

 

A Seamless Process for Perfection

Operating the DM1100 C and DM1600 C is a breeze, and the dimensions of these machines play a crucial role in their versatility. The DM1100 C boasts a maximum width capacity of 1100mm, while the DM1600 C can handle widths of up to 1600mm. 

These dimensions are vital for two key reasons:

Handling Larger Parts: With the DM1600 C's impressive 1600mm width capacity, you can effortlessly feed and process more substantial parts. This capability opens up new possibilities for working with larger components, expanding the range of applications for these machines.

 

Efficient Batch Processing: The generous width capacity also allows for the simultaneous processing of multiple small parts on the conveyor belt. This means you can maximize efficiency by deburring and rounding edges on numerous small components in a single run. Whether you're handling large or small parts, these machines adapt to your needs with ease.

 

As your part navigates its way through the conveyor belt, it encounters two sets of abrasive blocks working in opposing directions. This ensures that whether you're working with smaller laser parts or larger components, these machines have the capacity to meet your needs. As your part emerges on the other side, you'll be greeted with rounded edges, devoid of any rough surfaces or burrs, both on the inner and outer contours. This yields a sleek and professional finish that leaves a lasting impression.

Key Benefits of Our Edge Rounding Machines

Reduced Setup Time

Contrary to common belief, programmable controllers don't always simplify deburring machines. The non-EVO versions of our machines prioritize speed and simplicity. Thanks to direct input through hand wheels and straightforward on/off buttons, setup transitions from one job to the next in seconds. You can adjust material thickness, feed rate, and grinding pressure on the fly, all without interrupting the machine's operation.

Accelerated Operator Training

Training operators for these machines is a breeze, as minimal programming is required. As Steve Anderson, President of G.A. Systems Inc., attests, "Anybody can run it. You just set the height and let it do its work."

Reduced Component Failures

Complexity often leads to downtime. We've dedicated ourselves to simplicity, resulting in superior uptime for our C Equipment and a lower cost of ownership. Our machines are built for reliability and longevity.

Minimized Operator Errors

Easy-to-use machines lead to fewer operator errors. Operators can visually and intuitively monitor their inputs, preventing costly mistakes and ensuring a continuous flow of parts through the machine. This boosts operator confidence and productivity.

Your Partner in Deburring and Edge Rounding

Our edge rounding machines are the go-to choice for achieving top-tier deburring and quality edges on metal parts. Whether you're working with laser, punching or shear cut parts, small components, or larger metal pieces, our machines rise to the challenge. Bid farewell to manual edge rounding and embrace a more efficient process with our metal deburring machines.

If you have any questions about those finishing machines or need to make some tests please contact us through marketing@nsmaquinas.pt or on our contact page: https://nsmaquinas.com/contacts/. 

 

NEW DM1100 Z Light Burrs Removal Machine

The DM1100 Z is a machine designed for removing light burrs from metal parts cut by laser, punching, or shearing. It has a deburring station that is also capable of finishing flat surfaces such as metal sheets or other metal parts. This machine has a 1100mm width and a 120mm thickness processing capacity, compatible with practically all metal shapes and sizes within those limits. This adds to the machine’s versatility.




That versatility is further enhanced by the machine's high-grip conveyor belt, which makes it possible to process parts as small as 50x50mm, or even smaller, depending on their shape and dimensions. The pressure rollers placed before and after the abrasive belt station hold the parts in place during the grinding and finishing operation.



Configuring the aforementioned abrasive belt station is a fairly straightforward process. This deburring and finishing station includes an abrasive belt system with pneumatic tensioning for easy replacement of the consumables. It has a side switch meant to either tension the belt or releases it for the user to replace it with a new one. It also includes an automatic abrasive belt oscillation system to ensure that the belt is centered and does not move to either side during the deburring or flat surface finishing operation.


The machine is controlled with the frontal panel, where the operator can turn the abrasive belt unit and the conveyor belt on and off. The DM1100 Z also has an ammeter available to read the motor’s consumption and speed selectors with variable speed (for both the abrasive belt unit, ranging from 8 to 22m/s, and the conveyor belt, ranging from 1.5 to 7m/min). A manual thickness wheel with a 1/10mm-precision display is also included.



This operation is performed by the DM1100 Z’s deburring station, which uses an abrasive belt combined with a contact roller of 180mm in diameter and with a shore hardness of 55. This specific diameter and shore hardness make for the best combination for deburring and surface finishing. Bearing this in mind, the contact roller has a fine-adjustment feature to make the deburring station compatible with abrasive belts of different grits: from a compact grit all the way to scotch-type belts (i.e., from very thick abrasive belts to very thin abrasive belts).




There are two inverters built into the machine. These are essential for any deburring and surface finishing operation to be performed on laser-cut parts or metal sheets. The deburring process usually requires the conveyor belt to move at a slower speed and the abrasive belt station to move at a higher speed. The surface finishing process requires a higher speed on the conveyor belt and medium to high speed on the abrasive belt, depending on whether a compact-grit or scotch-type belt is being used. The combination of these two inverters allows for significant efficiency gains as far as the overall process is concerned and regardless of whether the customer needs to do deburring or surface finishing. Several advantages accrue to the user, namely the fact that very little heat is generated on the surface of the material. Other perks include there being less abrasive belt wear and the possibility of using different consumables on the machine.





This deburring machine was developed to meet several market requirements. It can be integrated with the DM1100 C, its edge rounding equivalent. Both can be connected through an extra conveyor belt table to allow for a complete deburring and edge rounding process. This table transports the deburred parts from the DM1100 Z to the conveyor belt of the DM1100 C to begin the edge rounding process. Customers who already have the DM1100 C Edge Rounding Machine can increase both their capacity and available services thanks to the addition of the deburring process made possible by the DM1100 Z.




NS Máquinas has also redesigned the old DM1100 C Parts Return System, creating a new version that allows both machines to be integrated. This solution ensures that one single user can operate both machines. They can feed the machine the parts, and the return system will bring them back to the operator. Therefore, the parts can be inspected and stored in the same place. There is no need for the operator to move around the machines. This solution is designed to bring back small parts up to 250x250mm and with a thickness of up to 20mm. Another advantage is the possibility of increasing productivity when a double-sided process is required. The operator receives the part and feeds it back to the machine, turning it over so the other side can be deburred, and its edges rounded out. The system is not fixed and can therefore be easily removed so bigger parts can be done.

If you want to know more information about this machine or book some tests contact us through marketing@nsmaquinas.com or on our website: https://nsmaquinas.com/contacts/.

Multiple Stations Deburring Machine

NS Máquinas’ deburring machines are designed to perform a complete metal finishing process, from burr removal to surface finishing. This allows any company to get rid of metal sheet imperfections and avoid problems later on with the painting process.

The new DM1100 DCC machine has three stations:

1) D – deburring drum for slag and burr removal;

2) C – cross belts for edge rounding;

3) C – cross belts for oxide layer removal.

This deburring machine has the same two stations that can be found on the DM1100 DC, seeing as both machines serve the same purpose (click here to read the article on the DM1100 DC). Compared to the DM1100 DC, this machine includes an extra cross belt station equipped with oxide removal cross belts. These special blocks use wires which grind against the laterals of the parts and remove the oxide layer.

At the drum station, the burrs are removed from the edges and the surface of the metal part. What happens afterward depends on how the customer prefers to configure the machine. Edge-rounding cross belts are the most common choice since it is enough for the parts to be painted afterward (usually using a powder coating process).

The right combination of stations assures that the part will only need a single pass through the machine, which helps reduce processing time. Other operations may be necessary and for that reason, it is possible to equip the machine with extra stations for 1) removing the oxide layer from the laterals of the metal parts or 2) obtaining a higher edge radius

          Oxide Layer Removal

When operating a laser cutting machine it is possible to use either oxygen or nitrogen. Nitrogen can be five to six times more expensive than oxygen. Also, the extra thermal energy provided by the oxygen allows for higher cutting speed. The main disadvantage of oxygen is the oxide layer that forms. This layer can prove problematic when doing powder coating or applying wet paint or other metal protection processes to the part because adherence is reduced, and they are therefore easily removed or likely to crack due to a small impact or movement.

Removing the oxide layer manually is a very time-consuming and expensive process. Usually, the high labor costs, the inconsistencies on the edges and laterals of the metal parts, and the fact that some parts are not easy to handle are the biggest disadvantages inherent to the manual process.

Automatic solutions are efficient when it comes to removing the oxide layer: the production rate is closer to the laser’s production rate and cost, and maintenance is not demanding when compared to using nitrogen to assist the laser. You can get consistent results in all the edges and laterals of metal parts. Oxide Layer Removal

       Extreme Edge Rounding

The metal coating protects metal parts from corrosion caused by environmental conditions and for this reason, it is one of the main processes performed after the deburring process. Different levels of exposure require more or less intensive coating processes. Usually, it is easy to apply a good layer of coating to flat surfaces. However, when dealing with the edges of the parts, problems tend to arise. If the edges are sharp or not round enough, the coating layer around them will be too thin when compared to the one applied to the flatter surfaces of the part. These specific points are the weakest ones and here the coating is likely to crack and expose the metal underneath, which will give rise to corrosion. By rounding the edges, it is possible to dull them and increase the surface area, thereby reducing the risk of corrosion forming around the edges. Adding an extra station for extreme edge rounding is a crucial step if your metal parts require a medium to high edge radius.

 

By combining those stations with a contact drum or an abrasive belt to remove burrs, it is possible to have an all-purpose machine with different possibilities for deburring, edge rounding, and oxide removal.

NS Máquinas is capable not only of delivering the best finishing machines for slag removal, deburring, edge rounding, oxide removal, and surface finishing but also of adapting them to suit each customer’s needs. For this reason, we equip our machines with the best systems and customize them to deal with any production issues or particularities our customers may have. Our deburring machines can be either standard solutions for the whole market or special solutions for specific production lines.

If you need further information about our machines please email us at marketing@nsmaquinas.pt or reach out to us through our contact page: https://nsmaquinas.com/contacts/.

High Radius Steel Plates

Creating a radius up to 2mm is often requested in steel plates as a preparation for powder coating or galvanizing. Achieving this R=2mm brings a much higher cost both in terms of abrasive consumables and in terms of processing time, so it needs to be clear this is really a necessary requirement. 

Several steel construction companies working on steel plates cutting for offshore, machine building, cranes construction and other steel fabrication require the deburring and edge rounding of these thick plates after oxy-cut or plasma cut. 

NS Máquinas achieves this result in 2 steps with the steel plated deburring and edge rounding machines DM1100 DC and DM1100 DCC or variations of these models which makes the steel metal sheets deburring and edge rounding faster.

Oxy Cut steel plate before deburring

1st: DM1100 DC contact drum eliminates heavier burrs by concentrating the pressure on the edges of the steel plates (oxy cut or plasma cut).

2nd: Once deburred, with a sequence of edge rounding abrasive brushes DM1100 DC creates a big radius on steel parts. 

See the results below:

DM1100 DCC 2.5mm radius 

The deburring and edge rounding process is relatively slow (conveyor belt speed under 0.5m/min), but the rounding is extreme and consistent. 

Measuring radius on steel oxy cut part

DM1100 DCC deburrs, deslags and edge round thick steel plates oxy cut or plasma cut. Its deburring solution and concept is quite unique and specially dedicated for thick steel plates deburring and edge rounding. The large diameter deburring drum D (Ø435mm) with extra soft rubber concentrates the pressure on the edges where the burr is located, leaving the surface of the material lightly touched only. Deburring contact drum floats every time there is extra pressure or to cope with small tolerances on the metal. This is particularly important in thick steel plates,

Edge rounding result is achieved by a sequence of abrasive tools assembled on a cross belt system. The pressure made by the deburring and edge rounding blocks, guided by a system where the pressure is controlled is key to achieve high edge rounding results. With different speeds we can obtain roundings from 1.8 to 2.3mm.

Contact us at marketing@nsmaquinas.com for further details or visit www.nsmaquinas.com 

Steel Parts Deburring and Oxide Removal

NS TESTS

Material: Steel Parts

Problem: Lateral Oxide Layer

Solution: Edge rounding combined with the oxide removal process

NS Máquinas received a request from a customer with steel parts with a layer of oxide on the lateral of the metal part. The metal parts had 12mm thickness and 200x200mm width.

Metal parts with an oxide layer on the lateral

The tests were conducted with a DM1100 C – Deburring machine which it is possible to equip with two different types of deburring blocks: edge rounding blocks and wire blocks for oxide layer removal.

It is possible to use the second blocks (oxide removal) with parts up to 20mm and ideally up to 16mm for better results. We process with two
different processes:

1)     One pass in each side of the parts to remove oxide layer and edge rounding;

2)     Two passes in each side of the parts to remove oxide layer;

All the tests were positive removing the oxide layer, check the following picture of the two samples:

On top: 1st process; On the bottom: 2nd process.

The total oxide layer was removed from all the sides of the metal sample. The edge rounding process is a choice for the customer considering that the machine allows both types of blocks. In this case, it was also suggested a double-side machine (DM1100 2C - Double-Sided Edge Rounding Machine) to decrease the processing time by 50%.

If you need to book your own deburring, edge rounding or oxide removal tests with us, please contact us through marketing@nsmaquinas.pt or through our contact page: https://nsmaquinas.com/contacts/ 

Deburring Machine with Automatic Return System - DM660 PK

Progress in technology has been changing the way companies in the industrial markets work. It's changing the way people work mainly due to the better tools and machinery. Now, more than ever, it is possible to make faster and better with the technology we have available. 

Operators from factories and workshops are now capable to enhance their working routine and automate most of the process. The increase of efficiency allow companies to manage their workers the best possible way, decrease unnecessary shifts, reduce wage costs, guarantee consistency and decrease workers capacity due to hard work overtime. 

Deburring systems are one of the most demanded processes after all the metal cutting machines like plasma or laser. Customers are requesting more and more quality in the material due to the final product requirements. The deburring process is the process responsible to remove the excess of material in the edge of the cut part. Removing the burrs is the first process in order to clean the part. 

After the deburring process, depending on the material are very sharp which is dangerous for handling the product and eventually not suitable for the final product. Considering this, usually it is included an edge rounding process where all the edges are rounded in order to decrease injuries in handling and/or to avoid the painting from peeling. 

Metal parts before and after deburring process 

Recently, NS Máquinas developed a machine which integrates a deburring machine with an automatic handling system. This deburring machine is capable to provide a radius up to 2mm which means it is a perfect machine for the edge rounding process. 

Deburring Machine with Automatic Return System for Long Parts

DM660 PK is a deburring machine which has two planetary abrasive brushes running in opposite directions. This system guarantees a uniform deburring process with perfect edge rounding in all the internal and external edges, even on small holes. The machine includes below the conveyor belt a magnetic to keep all the parts fix during the deburring process. 

The machine is also integrated with a Long Parts Return System which was developed to feed, transfer and return automatically long and heavy parts. 

The long parts return system has a the operator feeds the part in the first table which will load the machine with the metal part through the deburring station. In the exit there's two tables: one to remove the long part from the machine and the other one to send it to the next step. In order to demagnetize the parts, there's a third table which will pass the part through a tunnel which will remove its magnetic field. Finally, the fourth table will send the part back to the first table where the operator can inspect it and flip to make the double side deburring or store it. 

Please watch the video below about this deburring machine and the automatic system to have a complete idea of all the process: 

If you have any question don't hesitate in contacting us through our direct email marketing@nsmaquinas.pt or through the contact page on our website: Contact Page.

DM1100 DC - New Deburring System for Metal Parts

The new DM1100 DC debars and edge rounds inside and outside contours of thick steel parts cut by laser, plasma or oxyfuel. This deburring machine has a contact drum and a double cross belt station which performs edge rounding leaving soft and clean edges.

Burrs are grinded away from the edges with a powerful contact drum. This deburring drum has a large diameter with an extra soft rubber of 20SH for heavy burrs and thick material. The dry concentrate the pressure in the edges where the slag is located, leaving the surface of the material slightly touched only.

 
On the control panel, you can control all the options for the deburring drum station: fluctuation to cope with different metal tolerances and roller oscillation in order to improve abrasive paper lifetime.

The edge rounding station consists of a set of two counter-rotating edge rounding cross belts. The opposite rotation enables the edge rounding of all the contours: inside and outside. The result after this station is a soft edge.

This deburring machine features a magnetic table with 600mm width section. This area is essential for small steel parts processing to guarantee that even with substantial debarring pressure the parts will not move.

DM1100 DC machine includes as standard an automatic thickness measurement. The news developed system enables to easily slide the laser beam through the conveyor ti select the spot where the measurement will be done. The information of the thickness is sent directly to the PLC. There is also the possibility of integrating extra stations for oxide removal or even double side edge rounding.

If you need more information about this machine please send an email to marketing@nsmaquinas.pt or contact us through contact page.

Deburring Aluminum Extrusions

Deburring of the side of a thermal dissipation part used in an auto radio

Aluminum Extrusion Before Cutting Process

This small aluminum part has sharp edges all around the sides. This was due to the aluminum cutting process to create it.
Giving this, the customer needed to remove sharp edges and small burrs from this aluminum extrusion part.

NS DM1100 C edge rounding standard machine for edge rounding of metal sheets and small parts was the solution found for the edge problem. Due to the shape of the aluminum part it was not possible to put it in a straight position. In combination with guides on the top side of the conveyor table was enough to guarantee that the parts would be in the vertical position.

Frontal Part of the Deburring Machine - Guides for the Alumin Extrusions

The cross belts system combining two belts running in opposite directions are enough to deburr and remove sharp edges from this small part. The final result is a smooth edge due to the edge rounding process.

After and Before Process of Deburring Aluminum Extrusion

In combination with a special parts return system, the operator fed the parts in the table and then passes through the return system. After the inspection, the operator flips the part in order to deburr the other side. The parts return system enables the machine to operated with just one worker instead of several.

Parts Return System for Small Parts Inspection and Double Side Edge Rounding

For more information please visit our website: www.nsmaquinas.com or contact us at marketing@nsmaquinas.com

Plasma Parts - Deburring and Edge Rounding - DM660 ZC

One of the most known cutting processes for metal sheets is plasma cutting. This process uses a high velocity jet of ionized gas heating the workpiece and cutting by melting the material. Despite being a very economical and fast process, for thick metal sheets it has a big downside: big burrs.

Since the metal is melted, the top of the part has a clean cut but on the other hand the bottom remain with the burrs of the melted material. These burrs are, in most cases, undesired because changes the piece sizes and specifications. In order to be used on the final process, companies need to remove the burrs by implementing a deburring and edge rounding solution.

NS Máquinas developed the DM1100 ZC - Deburring and Edge Rounding Machine specially to remove medium and big burrs and perform the edge rounding in the same process. In order to do this, this machine, includes a deburring station with an abrasive belt and a large contact roller. Also, it has a double cross belt station with two belts running in opposite directions enabling the edge rounding.

The following sample is an example of the machine capacity:

Before and after deburring and edge rounding process

This piece has severe burrs on the bottom part and the costumer needed not only to remove it as well edge round and finishes the piece. After the deburring station the burrs were totally removed from the bottom surface. Also, giving the flexible cross belt abrasive blocks the edges of the part were soft and round.


For more information please visit our website: www.nsmaquinas.com or contact us at marketing@nsmaquinas.com.