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Deburring
Hand Deburring Tools
Info & Highlights
- Burrs are the unwanted portion of metal which remain at the edges of the components after machining
- Hand Deburring Tools offer Fast, Efficient & Economical solutions for removal of burrs. We offer wide variety of hand tools for Deburring of
- Tools/Blades of different shapes & Cutting Angles are suitable for different component materials such as Steel, Aluminium, Copper, Zinc, Brass, Cast iron, Stainless Steel, Alloy Steels, Variety of Plastics & 3D printed parts.
Orbitool - Cross Hole Deburring Tools
Info and Highlights
One of the most nagging problems in manufacturing is the deburring of cross-drilled holes. Burrs are always created where the crossholes exist. Getting at the burrs, let alone removing them, can be a real challenge.
A handful of methods are commonly employed for dealing with these burrs: sandblasting, extrude hone, and of course, manual deburring with knives, abrasive stones, brushes, burs, etc. While effective to varying degrees, these methods have their drawbacks. They’re all off-line processes, i.e. they are a separate operation. Parts need to be handled and/or moved from machining to deburring. Often deburring is an out-sourced operation. The extra handling, movement, queue, transport, etc. represent non-value added operations. Sandblasting, extrude hone, and similar devices involve capital investment, often substantial, or again, outsourcing. Manual deburring, as everyone knows, is very labor intensive, as well as craft sensitive.
- Why Choose Orbitool
- Applications
- Size and Selection Guidance
Consistent results and consistent quality
- Increased throughput / shorter cycle time
- Reduced deburring cost
- No setup for secondary deburring operations
- No batch and queue
- Ideal for controller process environment
Manual Deburring
Manual deburring is readily accomplished with ORBITOOL deburring cutters mounted in electric hand grinders (air grinders are not recommended-the rpm's are too high).
CNC Mill
The fundamental motion of the tool is helical. The machine tool controller should be capable of helical interpolation, i.e. simultaneous 3-axis motion control. The tool path is similar to thread-milling control. For mills without helical interpolation capability, a helix can be crudely approximated by combining circular interpolation with step-wise advancement of the tool in the z-axis.
CNC Lathe
With lathes the helical motion is accomplished by offsetting the tool axis with respect to the axis of the hole, then advancing the tool in the Z-axis. Lathes with live tools are easiest to outfit with ORBITOOL® deburring tools. Lathes without live tools can be fitted with moderately priced devices to run ORBITOOL deburring tools.
Process Demonstration
FAQ’s for Hand Deburring & Countersink tools
Life of the blades depends on the burr thickness and the material on which it is used. Choose the correct blade for the component matrial & the application. On softer material such as Al., Cu or plastic life is much longer than on the harder materials such as SS. As a thumb rule you can expect life of 460 meters (1500 feet) per blade on Mild Steel.
Our Deburring Info. page gives Application overview & the suitability guidelines of the different tools on the various component materials. Information on the recommended application is given on each product details.
Yes. For hole deburring /chamferring Countersinks can be used on drill press. For intersecting hole deburring – ORBITOOL can give excellent results. ORBITOOL can be used in hand held driver or can be used as in-process tool after drilling on CNC m/cs.
All our other tools are Hand tools.
A simple rule of 1/3 the speed of a drill of the same size will work for most countersinking
How to Calculate Countersink RPM Speeds
| Material | Surface Feet / Minute (SFM) | Sample Calculations for 1/4” Countersink Speed (RPM) |
| Aluminum | 200 – 250 | (225 (SFM) x 3.82 / .2500) /3 = 1,146 RPM |
| Mild Steel | 100 – 110 | (115 (SFM) x 3.82 / .2500) /3 = 586 RPM |
| Stainless Steel | 30 – 100 | (65 (SFM) x 3.82 / .2500) /3 = 381 RPM |
- Clean and smooth finish: Zero flute countersinks provide a clean and smooth finish to the countersunk hole. The absence of flutes in the tool eliminates the possibility of creating chatter or rough edges, leading to a more precise and polished finish.
- Reduced chatter: As there are no flutes in a zero flute countersink, it eliminates chatter and vibration, which means that the countersink can cut through the material smoothly without any wobbling or jumping.
- Enhanced performance: Zero flute countersinks are designed with a sharp cutting edge that can last for longer periods, eliminating the need to frequently sharpen or replace the tool. It also reduces the possibility of tool breakage, increasing efficiency and productivity.
- Versatile: Zero flute countersinks are suitable for use in a wide range of materials such as aluminum, brass, copper, steel, and plastics.
- Cost-effective: Zero flute countersinks may seem more expensive than other countersinks initially. However, due to its enhanced performance and longevity, it remains cost-effective in the long run as it reduces the need for frequent repairs and replacements.
- Easy to use: Zero flute countersinks are easy to use and require less effort to achieve high-quality results. It makes them ideal for DIY enthusiasts, professionals, or beginners.
A hand deburring tool is an essential tool for removing burrs and other unwanted materials from metal surfaces. It is important for the following reasons:
- Improve Surface Finish: A hand deburring tool can help improve the surface finish of metal parts by removing burrs, sharp edges and other unwanted materials. This improves the quality of the final product and enhances its performance.
- Safety: A deburring tool helps to remove sharp edges and burrs that can cause injury to the operator or other users of the product. By using a deburring tool, you can ensure that the product is safe to handle and use.
- Efficiency: A hand deburring tool can help reduce manufacturing time and cost by eliminating the need for additional processes such as grinding, polishing or sanding. This makes the production process faster and more efficient, leading to improved productivity and profitability.
- Increased tool life: Burrs can cause wear and tear on machinery and tools. By removing them with a deburring tool, tool life can be extended, reducing replacement costs.
- Consistency: Using a hand deburring tool ensures consistency in the quality of the finished product. This is important for products that require precise tolerances and accurate measurements.
In conclusion, a hand deburring tool is an important tool for any workshop or manufacturing facility. It improves safety, efficiency, tool life, consistency and overall product quality.
FAQ’s for ORBITOOL
Flexible holder will not be required. Flexibility of cutter shaft is sufficient in over 99% of the applications.
As regards the tool life, it is difficult for us to predict this. However to give you some rough numbers:
A common material like 316 stainless has resulted in an Orbitool tool life of 10,000 holes per cutter. Some customers have even seen 15,000 holes per tool. On aluminium, we’ve seen customers use a single tool for 40,000-50,000 holes. Of course, more exotic materials like titanium, Inconel, hasteloy, nitronic (common aerospace materials) might only result in a few thousand holes per tool. Adding another variable to the issue, is the required radius & thickness of burr. If a particular edge requires a larger radius or has heavy burr (for example, double the size of another hole), then an Orbitool will theoretically have to spend double the time, and remove double the material on that one hole. This would cut the tool life by half.
To maximise life from the Orbitool, control the burr to minimum by changing the drills regularly. Controlling burr by changing less expensive drill is always a better option.
All of this means to say, that we will not know the tool life until you test the tool and begin using it for some time.
Guide for using Orbitool on VMC or on CNC Turning is similar. Relative motions are different & you need live tooling for Orbitool rotation on CNC lathe. With CNC lathes the helical motion is accomplished by offsetting the tool axis with respect to the axis of the hole, then advancing the tool in the Z-axis. Lathes with live tools are easiest to outfit with ORBITOOL deburring tools. This video shows Orbitool cutter with flexible holder. This was shot during early period of Orbitool development.