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.
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 | ||||
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| ||||
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.
