Nylon Abrasive Filament Brushes (Nylox) Tools For Automatic Deburring & Finishing

Understanding Nylon Abrasive Filament (NAF) Brushes - Compliant Tools for Automatic Deburring and Finishing

Abstract:
Nylon abrasive filament (NAF) brushes solve many deburring, edge radiusing and finishing problems. Their compliancy and filamentary nature accommodate part contours, prevent damage to value added components, and make them ideal candidates for robotic and automated work stations. These brushes replace tedious hand operations, provide consistent quality, improve productivity, shorten cycle times, improve part finishes, generate precise edge radii, and lower finishing costs. This paper discusses guidelines to engineering automated deburring solutions using NAF brushes. Applications include blanked steel components, carbide inserts, aluminum aircraft parts, and automotive components such as camshafts, cylinder heads, wheel rims, and tranmission housings and valve bodies.
1. Introduction to Nylon Abrasive Filaments:
Nylon abrasive filament (NAF) brushes have been providing automated deburring solutions for many complex part shapes. These tools evolved over the past decade to cope with the increasingly stringent requirements of state-of-the-art manufacturing. Shorter cycle times, tighter part tolerances, improved part finishes, precise edge radii and lower deburring costs are easily achieved by employing NAF brushes in CNCs, robots and other automated deburring set-ups. NAF brushes are made of heat stabilized nylon filaments impregnated with abrasive grain, as shown in Figure 1. Working like flexible files, they conform to part contours, wiping and filing across part edges and surfaces. This action deburrs, edge blends and surface finishes parts. Filament configurations available are round crimped, round straight or rectangular. Rectangular filaments, having a larger cross section, are stiffer than round filaments, and, therefore, are more aggressive. They also provide greater abrasive contact with the work surface, as shown in Figure 2.
Figure 1: Enlarged View of Nylon Filaments
Impregnated with Abrasive Grain
Figure 2: An Illustration of Nature of Contact of Various
Filament Configurations with Work Surface
Nylon, an ideal material for a brush filament, has excellent toughness and fatigue properties as well as moisture, abrasion and chemical resistance compared to other polymers [1]. Also, its good memory (ability to return to its original position after being deformed) lends itself to brushing. Nylons used in the production of nylon abrasive filaments are Type 6, Type 66 and Type 612. Of these, Type 612 offers the most heat resistance and is preferred in industrial applications. Normal percentage of abrasive grit weight to total filament weight is 20-40%. Abrasive grits commonly used in nylon filaments are silicon carbide and aluminum oxide. Filaments with cubic boron nitride (CBN) and diamond abrasives are also available, but have not yet found wide spread use. Silicon carbide has excellent hardness, toughness and sharpness, and is cost-effective for use in nylon filaments. The silicon carbide used in these filaments has less than 0.1% iron oxide and no free iron. Therefore, filaments with silicon carbide can be used on non-ferrous metals, such as aluminum, without a chance of corrosion from iron contamination [1]. Because aluminum oxide is tougher than silicon carbide, it is less likely to fracture, and is used for finishing softer metals. It is also used when risk of carbon contamination raises concern in "hi-tech" applications, especially in the aircraft, aerospace and bio-medical fields. Although diamond and cubic boron nitride are harder than silicon carbide, their high cost (almost 100 times more than silicon carbide) prevents their wide spread use. Further, the softer nylon filaments wear away long before these expensive, harder abrasives wear out. Abrasive grits in round filaments generally range in size from 46 to 600; grit sizes available in rectangular filaments vary from 80 to 320. These grit sizes represent the mesh (sieve) number used in abrasive particle separation. Smaller grit numbers relate to coarser (larger) grit particles. In round filaments, grit size decides filament diameter (coarser the grit, larger the filament diameter) as shown in Table 1. Rectangular filaments, regardless of grit size, are offered in .045" x.090" (~1.1 mm x 2.3 mm); although other rectangular filament sizes are available.
Table 1: Typical Nylon Abrasive Filament Diameters and Grit Sizes
* Grit Size corresponds to the mesh number used in abrasive particle separation
Although grit sizes range from coarse (46) to fine (600), NAF brushes are not high material removal tools like grinding wheels or coated abrasive products. They only remove very "small" amounts of material, changing surface characteristics and improving micro finish. Figure 3 shows relative material removal (and surface finishing capabilities) of NAF brushes as compared to grinding and coated abrasive products. As shown, grinding and coated abrasive products can be high material removal tools, but NAF brushes, metallic wire brushes and non-woven abrasive products are surface finishing tools. The manner in which abrasives are held in the above products governs their material removal and surface finishing capabilities. For instance, under a specific condition, an 80 grit coated abrasive belt and an 80 grit rectangular NAF wheel brush were run on a mirror finished surface (4 痣n or .1 痠 Ra) to compare their finishes. The belt made deeper scratches and removed larger amounts of material compared to the NAF brush. On measuring the finish, it was found that the belt generated a 100 痣n. or 2.54 痠, (Ra) finish. The NAF brush, even with aggressive rectangular filaments, only produced a 30 痣n. or .76 痠 (Ra) finish.
Figure 3: A Chart Showing Relative Material Removal
(Surface Finishing) Capabilities of Various Material
Removal/Surface Finishing Products (Source: Anonymous)
2. NAF Brush Configurations:
Nylon abrasive filaments are used in various brush configurations such as wheel, disc, cup, end and tube as shown in Figure 4. They are used on automated equipment such as CNCs, robots and other specially designed automated set-ups. They are also used on manual and semi-automated equipment such as air and electric portable tools, bench/pedestal grinders, buffing and polishing lathes, drill presses and milling machines. These brush configurations are used to process different part geometries under various operating conditions. Some applications using wheel, disc and cup brushes are later discussed under case histories.
Figure 4: Different Configurations of
Nylon Abrasive Filament (NAF) Brushes:
Wheel, Disc, Cup, Tube and End
3. Benefits of a NAF Brushing Process:
The NAF brushing process offers several benefits to the end-user:
During use, sharp new abrasive grains are constantly being exposed as nylon wears against the work surface. This provides consistent brushing action throughout the brush life.
These brushes accommodate various part contours due to their compliance and filamentary nature.
Their compliance accommodates for small errors in part positioning and slight variations in part or burr sizes, making them good candidates for robotic and automated workstations [2].
Unlike rigid tools, their compliance also prevents damage to value added components, and hence minimizes/eliminates scrapping of components.
They lend themselves to automation, thereby making deburring and edge radiusing processes less labor intensive and time consuming.
Due to automation, medical conditions such as carpal tunnel and tendonitis can be prevented.
Under normal operating conditions, no coolant is required; therefore, no wastes are produced, leading to a clean and dry working environment.
Dedicated equipment is not needed, as they can be used on standard production machines, robots and automated workstations.
They allow machining and deburring/finishing operations in a single set-up, thereby eliminating the need for additional part handling or refixturing.
NAF brushing processes do not require part preparation or post cleaning, as may be required by some contemporary methods.
They cost-effectively replace tedious manual methods, non-woven abrasives, mass media finishing, buffs and compounds, abrasive flow/jet machining, air blasting, and thermal and electro-chemical deburring methods. Table 2 discusses some limitations of the contemporary methods that can be alleviated by using NAF brushes.
Table 2:
Limitations of contemporary methods of deburring and edge radiusing that can be overcome using NAF brushes.

4. Engineering a Deburring Solution using NAF Brushes:
Effective deburring solutions can be engineered by controlling the brush and process parameters (see Figure 5) that affect brush aggression and performance. Below are some guidelines to customize these parameters to suit your specific application.
4.A. Brush Parameters:
Tips on selecting brush parameters for effective deburring are discussed below:
4.A.1. Filament Configuration:
Use rectangular filaments for all applications except when:
reduced aggression is required; especially when processing softer metals such as aluminum and brass
added conformability offered by round filaments is required to accommodate a part contour.
larger, rectangular cross-section cannot get into the edges of small holes/slots and other features on the part.
Note: Using rectangular filaments with 80 grit abrasive grains will provide the most aggressive brushing to enhance productivity.
4.A.2. Grit Size:
Use 80 grit for all applications except when:
reduced aggression is required; especially when processing delicate parts and softer metals such as aluminum and brass
generating minimal edge breaks
producing a desired surface finish
smaller filament cross-section offered in other round filament grit sizes are more suitable to get into the edges of small holes/slots and other features on the part.
Note: Using rectangular filaments with 80 grit abrasive grains will provide most aggressive brushing to enhance productivity.
4.A.3. Abrasive Type:
Use silicon carbide for all general applications.
Use aluminum oxide only in cases where silicon carbide causes part discoloration or raises contamination concerns on certain non-ferrous applications.
4.A.4. Brush Diameter and Trim Length:
Brush diameter depends on the size and shape of the work piece, and process/equipment constraints. Some constraints include available spindle speeds, maximum brush diameter that can be used due to machine guard clearance or space limitation between brush face and work surface, etc.

Wheel brush diameters are sometimes chosen based on the trim lengths [1]. Generally larger diameter wheel brushes have longer trim lengths. Longer trim length is required to adapt to contoured parts and for parts requiring greater wiping and filing action. In many cases, each wheel brush diameter is available with various trim lengths to create different degrees of conformabilites and brushing characteristics. Disc brushes, however, are offered with a standard trim length unless customized to suit a specific application.
4.B. Process Parameters:
Tips on selecting process parameters for effective deburring are discussed below:

4.B.1. Depth of Interference (DOI):
DOI is analogous to depth of cut in machining. It depends on:
trim length - longer trim can accommodate greater DOI
spindle speed - slower spindle speeds [RPM] can allow greater DOI
part geometry - contoured parts require greater DOI to allow filaments to adapt to contours and wipe and file across all edges and surfaces
4.B.2. Spindle Speed (RPM):
Spindle speed depends on brush diameter, DOI and part geometry. Spindle speed, along with brush diameter, dictates surface speed (SFM). Usually, NAF brushes are operated at surface speeds below 3500 SFM (17.8 m/sec) to prevent overheating and smearing of the nylon onto the work surface. However, higher surface speeds can be accommodated by using coolants. Tables 3a & 3b show suggested spindle speed (RPM) ranges for various wheel and disc brush diameters.
Table 3a: Suggested Spindle Speed Ranges for Wheel Brushes
[1] Trim length is the free length of the filaments from hub to tip

Table 3b: Suggested Spindle Speed Ranges for Disc Brushes

When selecting spindle speeds from the above tables, 1. using a higher spindle speed in the range will improve brush aggression 2. using a lower spindle speed in the range will enhance brush conformability
Spindle speed, influenced by DOI, is generally decreased with increase in DOI. This ensures that the spindle speed and DOI combination allow filaments to conform smoothly to part contours. Such a combination insures that filaments are not hitting the part and bouncing off its surfaces, but are wiping and filing across its surfaces and edges. This brushing action also contributes toward longer brush life. Therefore, contoured surfaces are processed at slower speeds and greater DOI than flat surfaces.
4.B.3. Feed Rate:
Feed rate is determined by the amount of deburring, edge radiusing or surface finishing required, as well as type of material being processed. It is generally application specific. Slower feeds result in greater brushing action.
4.B.4. Coolants:
NAF brushes can be run dry; however, certain deburring conditions such as higher speeds and greater DOI combinations can create excess heat buildup, causing the nylon filaments to melt and smear on the work surface. To overcome smearing, coolants are recommended. Coolants are also recommended when working with CNCs and other automated setups to flush the burrs/metal particles and worn abrasive grit away from the precision machine components such as bearings, guides and slideways. The worn abrasive particles and metal chips in the coolants can then be trapped and removed by using a good filtration system with at least a 50 micron filter. This will minimize machine wear and tear, keep machines running clean, and keep airborne particles to a minimum. Coolants used are generally water-based.
4.B.5. Other Process Considerations:
Number of brush stations required: Once the brush and other process parameters are customized to provide maximum aggression, actual cycle time required to deburr a part can be established. If this cycle time does not meet the desired production rate, multiple brush stations may have to be set up. Brush path and rotation direction: For effective deburring, path and rotation of the brush(es) with respect to the part shape, burr location and burr orientation also need consideration.
5. Case Histories:
Some applications using NAF brushes are discussed in the following case histories. The abrasive grit used in all the case histories was silicon carbide.
Case History A: Automotive Cam Shafts
Problem: Deburr and radius edges of lobes and journals, remove heat scale, and provide surface finish below 20 痣n. or 0.5 痠 (Ra).
Solution: The process used 14" (360 mm) diameter, 180 grit crimped filament NAF wheel brushes at 1000 RPM, as shown in Figure 6. Long trim and slow speed allowed the filaments to wipe and file across the lobe and journal surfaces. The part was deburred, all edges of lobes and journals were radiused, and heat scale was removed. The final finish averaged about 16 痣n. or 0.4 痠 (Ra).

Figure 6:

Automotive Cam Shaft Being Processed
Under NAF Wheel Brushes

Processed (left) and Unprocessed (right)
Portions of a Cam Shaft
Case History B: Aluminum Engine Heads
Problem: Machining automotive aluminum cylinder heads leave burrs and sharp edges. Burrs could break away and interfere with the engine performance or even cause damage to moving parts. A process was required to deburr all edges on intake and exhaust valve faces, front and rear block faces, combustion face and cover rail of the cylinder heads on
a production basis.
Solution: Six disc brushes (5" or 130 mm and 14" or 360 mm diameter) with 180 grit round crimped filaments were used to deburr all edges. Brushes were used in a specially designed multi-station automated work cell as shown in Figure 7. Coolant used during this process flushed away loose burrs and abrasive particles, while it minimized air-borne dust and improved surface finish. This automated set-up can deburr 200 cylinder heads per hour [3].
Figure 7:
Automotive Aluminum Cylinder Heads Being
Deburred on a Multi-Station Automated Workstation

Deburring Exhaust Valve Face (in foreground)
and One Half of the Cover Rail (in rear)

Deburring Other Half of the Cover Rail (in foreground)
and Intake Valve Face (in rear)

Deburring Block Faces (only one face shown)

Deburring Combustion Face
(Photos: Courtesy of Acme Manufacturing)
Case History C: Steel Transmission Part
Problem: Deburr and radius inner and outer edges of the housing (Figure 8). Previous method used four 14" (360 mm) diameter .020" (.5 mm) carbon steel wire heavy duty knot wheel brushes on 4 machines. The brush head was lowered onto the rotating part to deburr it. Drawbacks of this process were short brush life due to wire breakage and poor part finish due to heavy steel wire working on the part edges.
Solution: As an alternative, a 14" or 360 mm diameter NAF wheel brush with 80 grit rectangular filaments, rotating at 1000 RPM, was suggested. Figures 8 shows the part before and after deburring. This process improved part finish and brush life, and offered considerable cost savings. NAF brushes cost 25% less per brush, and produced 1800 as opposed to 500 parts per brush.

Figure 8: Steel Transmission Part

Close-Up View - Before Deburring

Close-Up View - After Deburring
Case History D: Auto. Transmission Valve Body
Problem: Deburr and break the edges on the transmission valve body. Previous method attempted to deburr using a 6" (150 mm) NAF cup brush. Problems with this method were inconsistency and low production rates. Approximately 50,000 of these parts are produced each year.
Solution: A 6" (150 mm) diameter, 180 grit rectangular disc brush running at 325 RPM, 35"/min (15 mm/sec) feed rate, and .040" (1 mm) DOI, was used (Figure 9). This process consistently deburred the part, decreased cycle times by 3 to 1, and extended brush life by 5 to 1. The new method also provided an edge radius of about .005" - .008" (.13 mm - .20 mm) on all edges. Figure 9 shows the valve body before and after deburring.
Figure 9: Auto. Transmission Valve Body
Being Deburred Under a NAF Disc Brush
Valve Body Before Deburring
Valve Body After Deburring
Case History E: Automobile Wheel Rim
Problem: Machining the inside of automobile wheel rims produces burrs and sharp edges.
Solution: Depending on wheel shapes to be deburred, various diameter NAF cup and disc brushes are used on specially designed machines as shown in Figure 10. Although disc brushes are more aggressive tools that can offer shorter cycle times, the wheel rim shape shown in this figure required 3" (75 mm) diameter cup brushes to access recessed machined edges.
The wheel rims are fixtured and rotated between 0-24 RPM. Six brush heads, with variable speed and brush rotation reversing capability, are employed as shown in Figure 10. Cycle times vary from 20 to 60 seconds depending on the wheel shape and severity of burrs.

Figure 10: Automated Machine for Deburring
Automobile Wheel Rims Using NAF Cup/Disc Brushes
Close-Up and Cut-Away View of a Wheel Rim Being Deburred by NAF Cup Brushes (Photo: Courtesy of Hautau Specialty Machines, Inc.)
Case History F: Differential Component
Problem: Deburr hole edges on inside and outside diameters of part. Part was hand deburred in a very tedious and time-consuming process.
Solution: Using NAF brushes, the part was deburred in the same CNC set-up that machined it. A 3" (75 mm) diameter disc brush with 80 grit rectangular filaments and 3" (75 mm) trim was inserted into the part and rotated at 1750 RPM while being reciprocated. Brush rotation flared the filaments out, applying pressure against the inside walls of the part and deburring the hole edges (Figure 11). Hole edges outside the part were deburred with a 10" diameter (250 mm) 80 grit rectangular filament wheel brush running at 1200 RPM (Figure 11). Automation of deburring eliminated part handling, manual operation and increased productivity.

Figure 11: Differential Component:

Inner Walls of the Part Before Deburring

Inner Walls of the Part After Deburring
Case History G: Aluminum Aircraft Parts [4,5]
Problem: Deburring and radiusing parts ranging from bulk heads to spars and formers. Some parts range up to 4' (1.2 m) wide x 7' (2.1 m) long. Machining these parts involved a high degree of automation (using computer aided design, CNCs and robots). However, deburring and edge radiusing were labor intensive, time consuming hand operations using files, stones, small grinding wheels and cutters. Some were also tumble deburred.
Solution: An alternative was very long trim (above 8" or 200 mm) NAF wheel brushes used on a robotic system as shown in Figure 12. Their compliance and filamentary nature accommodated various part contours without damaging these value added parts. Furthermore, these features eased stringent requirements on part fixturing, robotic system accuracy, sophisticated control algorithms, and compensating for burr/part size variations. Compared to earlier methods, parts were deburred and radiused with improved consistency and part finish. A cycle time reduction from 4 hours to 45 minutes was reported on deburring bulk heads and spars. Parts were also stress relieved due to the dynamic action of the filaments, improving metal fatigue and stress corrosion.

Figure 12: An Aluminum Aircraft Part Being Deburred
by a Robotic Workstation Using NAF Brushes

(Photo: Courtesy of Cincinnati Milacron)
Case History H: Blanked Steel Plates
Problem: Grinding operation on blanked steel plates (4" x 6" x 1/8" thick or 102 mm x 150 mm x 3 mm thick) left feather burrs on the edges of the multiple surface holes and slots (Figure 13). The part needed a deburring, edge breaking and surface finishing operation in a single step. The initial Roughness Average (Ra) of the plates measured was 30 痣n. (.75 痠). The surface finish requirement was to have the Ra value below 19 痣n. (.47 痠).
The earlier process mounted the plates on rotating pedestals and fed axially through 2 brush heads. Each head contained a 25" (635 mm) wide stack of 10" (250 mm) diameter low density metal hub NAF wheel brushes, 180 grit crimped round filaments, running at 1000 RPM. Coolant was used during brushing. After brushing, the surface roughness was reduced from 30 to 17 痣n. (.75 to .43 痠). However, this method could not render all the plates 100% burr-free, as 40-60% of the processed plates had burrs left on them. The main deburring problem was around the 1/8" (3 mm) and 3/32" (2.4 mm) holes.
Solution: As an alternative, three 14" (360 mm) diameter disc brushes were employed; (1) 180 & (2) 240 grit crimped filament. Plates were fixtured on a conveyor and fed under the brushes, which eliminated the need for plate rotation. The 3 brush heads were staggered along the plate feed axis at 240 RPM with a depth of interference of .080" (2 mm) and a feed rate of 35"/min (14.82 mm/sec). No coolant was used. The result was 100% burr free plates (50 plates were inspected) with uniform edge breaks of .002" - .004" (.05 mm - .1 mm). Surface finish measurements ranged from 4.1 to 13.8 micro inches (.1 to .35 micro meters), although most were in the 8.7 to 12.8 micro inches (0.2 to .32 micro meter) range.

Figure 13: Blanked Steel Plate

Case History I: Steel Compressor Plates
Problem: Deburr and edge radius compressor plates after surface grinding (Figure 14). The main concern was to completely deburr and blend the edges of the three centrally located holes that were on a slightly lower plane than the plate surface.
Solution: The parts were fed under three 6" (150 mm) diameter disc brushes with 80 grit rectangular filaments on a rotary table automatic deburring machine as shown in Figure 14. The operating parameters were brush speed of 1750 RPM and DOI of .100" (2.5 mm). The reported brush life was 8000 parts per set of 3 brushes.
A production rate of 1200 parts minimum per 10 hour shift was a requirement in this case. Before employing NAF brushes on an automated set-up, 2 operators manually deburred 1200 parts in 10 hours. With NAF brush automation, the production rate was easily achieved by 1 operator in 5 hours. Instead of manually deburring the parts, the operator now had to just monitor the machine. NAF brush automation doubled their production capacity while saving 75% in labor costs. It also improved consistency of deburring and enhanced the working conditions by eliminating tedious manual operations leading to carpal tunnel, tendonitis etc.

Figure 14:

Steel Compressor Plate

Steel Compressor Plate Being Deburred by Automated
Machine with Three NAF Disc Brushes
(Photos: Courtesy of Hautau Specialty Machines, Inc.)
Case History J: Carbide Inserts
Problem: Obtain precise edge radii on carbide inserts ranging from .0001" to .008" (.003 mm to 0.2 mm). Precise edge radii enhance life and performance of inserts by removing loose burrs and microscopic defects from the edge, and adding strength and impact resistance.
Solution: Many insert manufacturers today employ NAF wheel brushes for this operation. Inserts are fixtured on rotating pedestals positioned on a rotary table (see Figure 15), and fed under the brushes. Figure 15 shows carbide inserts before and after edge radiusing.Typically, brush diameters ranging from 10" to 14" (250 mm to 360 mm) are used. Based on the specific need of each manufacturer, filaments used range from 500 to 46 grit crimped round, and 80 and 180 grit rectangular to achieve production rates of over 500 inserts per hour. One manufacturer requiring a radius of .001" to .002" (.03 mm to .06 mm) reported using 6 NAF brushes per head on a 2-head rotary head machine, and producing 62,000 inserts over the life of the brushes [4,6].

Figure 15:
Carbide Insert on a Rotating Pedestal Being Deburred Inserts Before (left) and After (right) Edge Radiusing (Photos: Courtesy of Harper Surface Finishing Systems, Inc.)
Case History K: Aluminum Extrusions
Problem: Deburring saw cut ends of various shapes of aluminum extrusions as seen in Figure 16. Previous methods used hand files, wire brushes and sanding discs, depending on part shapes.
Solution: NAF brushes in both wheel and disc configurations are very conducive to deburring various extruded shapes. Their compliance and filamentary nature adapt to various shapes, thereby eliminating the need for tool selection based on part shapes. Normally, brushes with 180 grit crimped filaments are chosen. The 180 grit crimped filaments provide adequate aggression on soft metal like aluminum without sacrificing
part finish. The brush shape (wheel or disc) selected is an end-user preference, and often depends on the equipment available. The brush diameter is selected based on part size and other process/equipment constraints. Figure 16 shows extruded shapes before and after deburring.

Figure 16:

Various Shapes of Aluminum Extrusions
Aluminum Extruded Shape Before (left) and After (right) Deburring
Case History L: Turbine Blades
Problem: Deburr and edge radius with a required radii range from .005" to .030" (.13 mm to .76 mm). Figure 17 shows a photograph of a turbine blade. Non-woven abrasive deburring wheels were used in an off-hand, manual operation. Process resulted in poor product life and inconsistent finish due to dependency on manual labor.
Solution: 14" (360 mm) diameter, 120 grit round straight filament, hub brushes running at 1200 RPM in an automated set-up improved the process. Parts were rotated against two brush heads rotating in opposite directions. The brushes improved cycle time and production cost while providing a more consistent finish. Figure 17 shows close-up views of a turbine blade before and after brushing.
Figure 17: Turbine Blade
Close-Up View of Turbine Blade - Before Deburring Close-Up View of Turbine Blade - After Deburring
6. Conclusion:
NAF brushes are excellent solutions for automating deburring and finishing operations. They replace tedious manual operations, provide consistency, and improve productivity. These tools adapt to part contours, lend themselves to automation, and provide an environmentally safe process.
Applications include, and are not limited to, deburring and edge radiusing of: Gears (steel, powdered metal, cast iron) Cast aluminum engine blocks, transmission housings Cast aluminum auto wheels Blanked steel components Cut ends of aluminum extrusions Cast iron intake manifolds Carbide inserts Powdered metal components Surface finishing of softer metals (such as aluminum, zinc and brass) and steel to produce decorative finishes or lowered micro finishes
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References:
1. Watts, J.H., "Abrasive Monofilaments - Factors that Affect Brush Tool Performance", SME Deburring and Surface Conditioning Conference, MR89-112, San Diego, CA, February 13-16, 1989.
2. Dawson, B.L., and Hennies R.C., "Robotic Long String Brush Deburring System, SME Robots and Vision Conference, MR88-297, Detroit, MI, June 6-9, 1988.
3. Vaccari J.A., (Ed.) "Aluminum Engine Heads Deburred Automatically", American Machinist, pp 45-47, December 1993.
4. Hettes, F.J., "Brush with Success", Cutting Tool Engineering, pp 39-42, June 1992.
5. Dawson B. L., "Automated Surface Finishing", Aerospace Engineering, pp 25-2