Edge Rounding Optimization with DM1100 C

 Edge Rounding Optimization with DM1100 C

At our test center, we recently carried out production trials using the DM1100 C machine to evaluate edge rounding and surface finishing techniques tailored to specific customer requirements.

Objective

The customer requested tests to achieve an edge rounding of R=2mm on their steel parts. To ensure the best solution, we conducted a comparative test using two types of abrasives: Crossbelt Purple Radius and Green Flex, applied on opposite faces of the same part.
As the parts will be painted after processing, the R=2mm rounding is not a strict requirement.
The customer’s main focus is achieving a uniform edge rounding, while burr removal is a secondary operation.

Testing Parameters and Process

Machine used: DM1100 C

The customer sent 8 samples with different thicknesses, and the tests were organized to present the best solutions to meet their specific needs. The parts were labeled from A to G to allow for a clear analysis of the results.
One highlight is part C, where a special test was carried out: side C.1 was processed using the Green Flex abrasive, while side C.2 was processed using the Purple Radius. This procedure allowed the customer to compare the results of both Crossbelt abrasives on the same part.
All parts were tested under the same feeding speed conditions (0.8m/min).

The customer is a company specializing in the production of non-standard steel, stainless steel, and aluminum structures. They implement the full production cycle of metal structures, starting from design to the painting of finished products. With modern and efficient equipment, along with highly qualified personnel, they ensure quick and high-quality execution of customer orders.
They produce a wide range of products, including heavy vehicle cabs and parts for the motor industry, components for snow and ice removal equipment used at airports, various containers for goods transport, including those for military needs, and building structures. Finished products are primarily exported to the Nordic countries.

 

A
B
C.1
C.2
D
E
F
G

Abrasives tested

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

Results and Best Performances

In the images, it is possible to observe that the parts exhibited good rounding, meeting the customer's expectations when using the Crossbelt Green Flat. A noticeable difference in edge rounding was observed in parts treated with the Purple Radius, especially in parts with thicknesses greater than 15 mm and 20 mm, which require higher load. The main disadvantage of the Purple Radius compared to the Green Flat is the higher consumable wear, which, although it has a greater grinding capacity, tends to wear out more quickly. It is worth noting that all parts were tested under the same feeding conditions and Crossbelt speed.

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 Enhancement with DM1100 C

Edge Rounding Enhancement with DM1100 C

At our testing center, we recently conducted production trials with the DM1100 C machines to assess edge rounding and surface finishing techniques tailored to specific customer needs.

 

Test Objective

A customer requested tests to achieve the best possible edge rounding while ensuring the finish followed the direction of the longest side of the part. To ensure the most effective solution, we performed a comparative test using the Purple Radius Crossbelt abrasive. In the process, we applied the finish parallel to the longest side on one piece, while on the second piece, we positioned it diagonally to maximize the impact on all edges. Both pieces received finishing on both sides.

 

Customer Profile

 

The customer is a manufacturer specializing in the production of high-precision fastening systems for the automotive and construction industries, offering a range of innovative and reliable solutions for connecting and securing various components.

 

Testing Parameters and Process

Machine used: DM1100 C

 

The customer sent two samples with the same thickness (0.8mm), and the tests were conducted to find the best solution to meet their needs. The parts were labeled A and B to ensure a clear and objective analysis in the report.

On part A, we strictly followed the customer's request, rounding the edges on both faces with the lines parallel to the longest side of the part.
On part B, we applied our recommendation, positioning the piece diagonally on the belt to maximize the impact on all edges and optimize the final result.
Both parts were tested under the same conditions, with the feed rate set to 0.8 m/min and the crossbelt speed adjusted to 8 m/s, ensuring consistency and comparability of the tests.

A
A
B
B

Abrasives tested

 

Crossbelt Purple Radius

A 3-row cut design with 60G ceramic + purple fleece, known for its efficiency in edge rounding applications.

 

 

Results and Best Performances

In the images, it is possible to observe that both parts achieved excellent edge rounding, meeting the customer's expectations thanks to the use of the Crossbelt Purple Radius abrasive. The difference in the finish between the diagonally positioned part (B) and the horizontally positioned part (A) is clearly visible.

Nevertheless, both parts show a similar level of edge rounding. It is important to highlight that all tests were carried out under the same feed rate and crossbelt speed conditions, ensuring consistency and comparability of the results.

 

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.

 

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.