Burrs are edges, splinters or fraying on workpieces that occur during turning, milling, drilling or grinding. They often impair functionality, for example due to low fitting accuracy or poor thread run, and can cause deep cuts. For this reason, workpieces are deburred by various methods:
By choosing the right tool and sharp cutting edges, the formation of burrs is already reduced during turning, milling or drilling. The deburring of workpieces, for example made of stainless steel or aluminum, is nevertheless a very important work step for accurately fitting, safe workpieces.
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Hardening is a heat treatment process that increases the mechanical resistance of metals such as stainless steel or aluminum by changing the structure of the material.
Transformation hardening is the most important hardening process for steel. Steels are suitable for hardening from a carbon content of 0.2%. Otherwise, they must be carburized before hardening. Precipitation hardening is the main way to increase the strength of certain aluminum alloys and is often used for aerospace applications, for example.
In both transformation and precipitation hardening, the workpiece is first heated, the temperature is maintained, and then quenched. Depending on the material, a different temperature and cooling rate is selected for hardening, and too high a rate can cause cracking. Water with or without additives, oil, salt bath, air or pure gases, for example nitrogen, are used for quenching.
After quenching, steel is "glass-hard", i.e. very hard and brittle. During tempering, also known as annealing, the workpiece is therefore heated again to 100 to 600 °C to remove its internal stresses. The higher the tempering temperature, the softer but also tougher the material becomes. The tempering temperature therefore influences the subsequent service properties.
The combination of hardening and tempering is called quenching and tempering. Quenching and tempering is one of the through-hardening processes (through-hardening) that work right into the core of the workpiece. In contrast, surface hardening, such as case hardening, hardening by laser or electron beam, flame hardening and induction hardening, only changes the outer layer.
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During the machining of metal, for example during turning, milling, drilling or heat treatment, cracks can occur due to stresses in the microstructure. Particularly under demanding loads, the smallest damage in components expands over time and can lead to total failure of the component. In the case of safety-relevant parts subjected to extreme to maximum loads, such as aircraft turbines, brake discs, axles or steering parts, the consequences are life-threatening. Crack detection is therefore an important part of quality assurance, both for individual parts and for series. In many industries, for example in the automotive and aerospace industries, standards are defined for the inspection of components prior to installation.
A distinction is made between destructive and non-destructive testing of materials such as stainless steel or aluminum:
By its very nature, destructive crack testing can only take random samples and causes a lot of rejects. There are several options for non-destructive crack testing, depending on the material and the objective:
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After turning, milling, drilling or grinding, it is important to remove impurities on the surface of the workpiece, for example chips and residues of cooling lubricants, grinding and polishing agents. Ultrasonic cleaning cleans gently and thoroughly and is also suitable for complex component geometries and workpieces with hard-to-reach areas such as cavities, boreholes and threads. For this purpose, the workpiece is immersed in an ultrasonic bath. The sound waves in the range from 20 kHz to 4 MHz cause the liquid to vibrate, thus loosening even firmly adhering contaminants by overcoming the adhesive forces.
Ultrasonic cleaning produces an excellent result and is suitable for metals such as aluminum or stainless steel and a variety of other materials. Used parts can be reconditioned by ultrasonic cleaning, as even stubborn dirt such as lime or combustion deposits are removed.
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