Technical Report on Burr Removal Using Plasma Equipment

 

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📘 Technical Report on Burr Removal Using Plasma Equipment

– Including Types of Plasma Systems and Burr Types –
Source referenced:

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1. Introduction: The Necessity of Burr Removal

A burr is a small, unwanted protrusion generated on the edges of metal, resin, ceramic, or other materials during machining processes such as cutting, drilling, milling, punching, plasma cutting, or laser cutting. Burrs reduce assembly accuracy, lower performance, cause particle contamination, damage components, and generate safety hazards. Therefore, burr removal is essential, especially in precision industries.

Plasma deburring offers a non-contact, precise, and low-damage method, showing advantages over conventional mechanical grinding or chemical etching due to its speed, cleanliness, and easy automation.

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2. Types of Burrs

Burr Type Cause Characteristics

Mechanical Burr	Drilling, milling, lathing, punching	Sharp, hard protrusions created mechanically
Thermal Burr	Laser or plasma cutting	Molten metal resolidifies, containing slag/spatter
Rollover Burr	Shearing process	Rolled-over edge caused by compression
Poisson Burr	Lateral expansion under compressive load	Thin, spread-out burr
Micro Burr	Semiconductor, microchannel, precision machining	Very small, often invisible to the eye
Flash	Injection or extrusion molding	Thin overflows at mold gaps, easily removed with plasma

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3. Operating Principle of Plasma Burr Removal

Source referenced:

Plasma equipment generates high-voltage, high-frequency electrical discharge between electrodes and the workpiece, creating plasma composed of electrons, ions, radicals, and UV. These species interact with burrs as follows:

3.1 Plasma Reaction Mechanisms

1. Ion/Electron Bombardment (Sputtering)
   • High-energy particles collide with the burr surface → weakens bonding forces.
2. Thermal Weakening
   • Burrs have lower heat capacity than the bulk material.
   • Plasma heats the burr → rapid brittleness → detachment.
3. Chemical Decomposition (Etching)
   • Activated species in O₂, Air, Ar plasma induce
     oxidation, reduction, or molecular decomposition, weakening the burr.
4. UV and Ozone Effect
   • Plasma-generated UV and ozone break down organic burrs or flashes.
5. Air-Blow Assisted Removal
   • Detached burrs are expelled with air jets for complete removal.

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4. Types of Plasma Systems for Burr Removal

Source referenced:

4.1 Atmospheric Plasma (DBD Type)

• Dielectric barrier discharge (DBD) structure using ceramic electrodes
• Low-temperature plasma suitable for metals, plastics, composite materials
• Advantages: minimal thermal damage, suitable for automated lines

4.2 Plasma Jet System

• Plasma is ejected through a nozzle
• Ideal for micro-burrs and narrow locations
• Easy integration with robotic or conveyor systems

4.3 Electro-Plasma Hybrid Deburring

• Example: Plasmotion system
• Workpiece submerged in electrolyte; burr removed through combined
  plasma + electrochemical reactions
• Extremely fast: a few seconds per part
• Excellent for micro-deburring and fine edges

4.4 Laser-Induced Plasma Deburring

• Laser induces localized plasma to remove micro-burrs
• Used in semiconductor channels and precision components

4.5 Thermal/Arc Plasma Slag Removal Systems

• Removes thick burrs, slag, and molten residues left after thermal cutting
• Used for heavy plate processing and structural components

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5. Key Design Parameters for Plasma Deburring

Source referenced:

5.1 Electrical Parameters

• Voltage: selected based on burr size and material type
• Frequency: controls discharge stability
• Current density: must be optimized to avoid thermal damage

5.2 Mechanical Parameters

• Electrode–workpiece distance (gap): adjusted to part size and shape
• Nozzle angle & speed: tuned based on burr orientation
• Airflow: used for cooling and debris expulsion

5.3 Cooling & Safety Considerations

• Prevent overheating that could deform the material
• Air cooling or shortened processing time should be used to avoid thermal damage

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6. Plasma Burr Removal Process Steps

1. Burr detection (sensor or CAD-based)
2. Alignment of discharge head
3. Plasma discharge (bombardment, decomposition, weakening)
4. Air-blow removal of detached burrs
5. Inline inspection with camera/sensors
6. Transfer to next process step

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7. Advantages of Plasma Burr Removal

Category Benefit

Non-contact	No mechanical stress on parts
Micro-burr removal	Handles burrs that conventional grinding cannot remove
Minimal thermal deformation	Low-temperature plasma protects the workpiece
High uniformity & automation	Easy integration with robots and high-speed lines
No reattachment	Air-blow prevents re-contamination
Eco-friendly	No chemicals used

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8. Application Areas

• Automotive parts (gears, valves, injectors, housings)
• Medical devices (stainless steel, titanium)
• Semiconductor microstructures and microchannels
• Aerospace components (turbine, engine components)
• Post-processing after laser/plasma cutting
• Plastic injection molding flash removal

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9. Important Precautions

Source referenced:

• Excessive voltage/frequency may damage the material → optimization is required
• Use cooling air to prevent thermal deformation
• Maintain consistent discharge gap
• Choose gas types carefully to prevent oxidation or burn marks

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10. Conclusion

Plasma deburring is a highly efficient, precise, and environmentally friendly process.
It provides:

• High precision,
• Automation compatibility,
• Low thermal and mechanical damage,
• Superior burr removal quality.

As micro-burr control is critical in industries such as semiconductors, medical devices, and automotive components, plasma technology is expected to expand significantly across advanced manufacturing fields.

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If you’d like, I can also prepare
✔ a PPT version,
✔ a catalog-style summary, or
✔ isometric drawings of the equipment.

 

 

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Reference, #References #PlasmaSterilizationSpecialistPlasmaLife
https:///http://www.plasmakorea.com PlasmaLife Co., Ltd. hyeonji63@gmail.com
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