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.