Abrasives are a much-needed tool for manufacturers but can quickly become problematic when used inside CNC machines.
Unlike grinding machines, or finishing systems like the MAX, CNCs are not built with bagged filtration systems that are able to handle the loads of swarf produced during product cycles. While they might include circulatory pumps, they don’t have the necessary systems that are able flush out and rid the machine of these larger damaging particles.
Not only do the chips removed by the abrasive collect within the machine, particles from the abrasives themselves will also clog it. There’s a misconception that brushes are gentler abrasive tools and don’t shed like other abrasives, so many people will put them inside of their CNCs thinking they will be less harsh than other methods. But brushes wear down too, and that matter doesn’t just disappear—it gets ground off into a thin dust which will also settle along the bottom of the machine. These brushes use materials such as zirconia alumina, ceramic, aluminum oxide, and silicon carbide, just as other abrasive tools do.
“People think brushes are different because they don’t create sparks,” clarifies Scott Richards, Vice President of James Engineering, “but if you research [their] active ingredients you’ll see they use the exact same kind of abrasive.”
There’s a handful of materials commonly used as abrasives:
1. Zirconia
As a more rigid abrasive, zirconia tends to last longer than other materials and is capable of withstanding more intense usage and higher pressure. Due to its thickness, it is best used on tougher materials, such as stainless teel and titanium. Higher volume/intense operations tend to prefer zirconia because of its durability, even though it comes at a higher price.
2. Ceramic
Ceramic is very versatile, making it useful for a number of different operations. As an organic material, it has an extended shelf life and tends to stay sharper for a longer period of time. It’s not the ideal choice for cutting parts, but it’s perfect for operations such as deburring, grinding, polishing, etc.
3. Aluminum Oxide
This material proves to be the most commonly used abrasive. Essentially a form of sandpaper, aluminum oxide is used for more delicate materials like wood and is preferred for small-scale operations that require a gentler approach. Extremely tough and highly resistant, it’s no surprise that it’s such a popular choice.
4. Silicon Carbide
Silicon carbide is not only one of the hardest abrasives, but it’s also able to withstand extremely high temperatures. Because of this, it can be found in almost all abrasive tools (grinding wheels, stones, sandpaper, etc.) as either loose or solid material. It’s not good for cutting, but great for chamfering (in fact, James Engineering sells a line of silicon carbide wheels that work perfectly for petite chamfers specifically).
What ends up happening inside of these CNC machines is the abrasive gets trapped and stuck between their ways and slides. These mechanisms require smooth movement, and when abrasive gets stuck in the oil barrier that helps these pieces of metal slide together, it starts to eat away at them with their continuous movement. “In a way, it’s like your creating sandpaper,” says Richards, “It’s literally wearing your machine out.” As these slides continue to work despite the abrasive, operators will notice the oil barrier turn black, a classic sign that there’s already a large buildup that’s been accumulated.
“Usually when people look for a deburring machine, they’re looking for one to do lots of parts. If we’re making just a couple of parts, one sheet of Scotch-Brite will last you several days, if not one week,” Richards explains, “That’s roughly one ounce of abrasive falling under your ways and slides. One ounce isn’t a big deal. But when our customers are deburring a part every 15 seconds, that’s a whole different scenario.”
Richards provides some math as reference—“For example, I’m thinking about [a company] that uses 4 ounce grinding wheels that wear out at 50 parts, and they run 5000 parts a day. That means they go through roughly 100 grinding wheels a day, which comes out to be 400 ounces—or 25 pounds—of abrasive deburred in a machine in a day.” For CNCs, this massive volume of abrasives can become detrimental in an extremely short period of time, which ultimately ends up costing shops more due to machine repair/replacement.
When shops produce at high volumes like this, having a machine made specifically for deburring is imperative to maintaining a smooth operation. Yes, CNCs are capable of deburring, but their true strengths lie in cutting parts. So when a CNC, a cutting machine, is paired with a deburring machine, such as the MAX System, shops can produce higher quality products at higher rates.
“The MAX isn’t trying to compete with CNCs,” Richards reassures, “It is meant to compliment CNC machines by letting them do what they do best: make parts.”
One of the key differences between the MAX and a CNC is that they MAX is made to handle abrasives of all different kinds. “Our machines can use anything that anyone can throw at it,” Richards states. “Scotch-Brite, grinding wheels, brushes… we’re designed for abrasive. We’ve taken away all sensitive ways and slides, replaced them with [overhead] linear motion… the MAX is resistant to abrasive.”
Digging into that a little deeper, Richards reveals that all of the MAX’s vital components are stored in the roof and can be retracted when not needed. This means that harmful swarf is unable to collect between the different mechanics and clog up the system. “Our machines that are out in the field and have been for 10 years are still showing no signs of wear—because of the design.” The MAX is also built with special bagged filters that ensure any leftover swarf is washed out of the machine; approximately 220 gallons of wash solution are pumped through it per minute, which not only cleans out the MAX but washes off the processed parts as well, preparing them further for assembly.
Abrasive doesn’t have to be, well, abrasive against your machines—by pairing your CNC with the MAX, you not only spare your CNC the pain of unnecessary wear, but you increase production quality and quantity. The MAX was created to be a partner to CNCs, not a competitor—seeing as it is unable to cut parts itself, it needs the CNC to complete its job! The MAX takes the abrasive out of CNCs so that they can put all their focus on cutting parts with long-lasting efficiency and precision.
If you’re tired of abrasive grating on your operation, invest in the MAX. Made to handle abrasives of any kind, it won’t back down from any project you may throw at it.
To learn more about what all the MAX has to offer, click here or call us at (303) 444-6787