Rounding edges with deburring machines

Rounding edges thin sheet metal





Deburring machines from WEBER
for precise edge rounding
for the highest standards

Most important

Edge rounding through innovative sanding technology 

Edge rounding is a crucial step in numerous manufacturing processes that is becoming increasingly important, especially when the demands on the cut edges increase and simple deburring is no longer sufficient. In contrast to deburring, which usually only means a slight edge break along the cut edges, the desired work step requires a defined, uniform rounding equal to a radius.

From the automotive industry to aerospace, from electronics production to medical technology - edge rounding plays a decisive role wherever precision, safety and quality are of the utmost importance. A uniform and precise result is essential for the quality of subsequent processes such as painting, powder coating or electroplating. In sectors such as the food and pharmaceutical industries, rounded edges on machines are often a prerequisite for meeting safety standards and hygiene regulations. Edge rounding is also used in areas such as offshore, shipbuilding, steel structures and bridge construction. Precisely rounded edges not only help to prevent injuries, but also extend the service life of products and increase their performance. In this context, our innovative sanding solutions offer the precision and efficiency required to meet the high demands of various industries.

WEBER technology

Whether punched, nipped or produced with laser cutting, deburring is essential for the further processing of metal parts. This places high demands on the grinding technology, which we master effortlessly with our WEBER grinding machines. 

The contact roller is at the start of the deburring process and plays a crucial role in processing the edges. Its function is to remove the burr evenly, which ultimately results in a smooth surface. The contact roller is particularly effective in pre-grinding, as it effortlessly removes even thick, melted laser spatter. To ensure precise control, the contact roller is precisely controlled and normally positioned slightly below the zero line, which allows for flexible adjustment of the sanding pressure and meets the requirements of a wide range of workpieces.
The actual sanding action is performed by the abrasive, which is pressed onto the surface of the material by the contact roller. Various types of rubberized contact rollers are used when sanding metal, with hardnesses ranging from 25 Shore to 60° Shore. These contact rollers are available in diameters from 135 mm to 450 mm, with a maximum contact length of just a few millimetres, which corresponds to line contact.

Contact roller unit

The MRB brushing system offers an optimum solution for precise edge processing and versatile material requirements for a uniformly shaped radius along the inner and outer contour. By arranging multiple rotating heads, consistent results are achieved across the entire working width. With two brushes per head, the system ensures consistent performance, even with materials as thin as one millimeter.

The outstanding performance of the MRB brushing system proves particularly effective on three-dimensional parts such as gills, thread pull-throughs and forming. It produces gentle radii on the edges without damaging the coating of materials such as foiled, galvanized or hot-dip aluminized sheet metal - even with thicknesses of less than 1.2 mm.

The precise operation of the multi-rotation brush, from bottom to top, guarantees even and gentle edge rounding. This not only enables accurate processing of different materials and shapes, but also significantly increases the efficiency and quality of the end products.
 

Multi-rotation brush
Multi-rotation brush

For perfect edge rounding, you can rely on our innovative planetary head systems “P6 and P2”, which are equipped with a variety of advantageous features.

Thanks to the unique combination of double rotary movement of the tool (planet) and planetary head housing (ring gear), we always achieve uniform rounding on both inner and outer contours. The tools are grouped together on planetary heads in a compact machining station.

Our brushes always work at the optimum angle on the workpiece. With our patented WEBER P2 solution, the tools of the adjacent planetary head gears overlap seamlessly to avoid gaps during machining. On the one hand, this ensures a better rounding result and, on the other hand, the abrasives wear less. 
The well-coordinated transmission ratio enables a wide speed range with powerful power transmission and a small size. This enables us to use a wide range of commercially available grinding tools. For a long and maintenance-free service life, our planetary heads are completely sealed and filled with a lubricant that reliably protects them from dust and dirt. This maintains the performance of the gears and effectively counteracts wear. Automatic tool length measurement enables quick, precise and uncomplicated readjustment of the tools. Only perfect settings produce appropriate results.

Planetary head system
Series Metal sanding machines

Discover our metal technology for edge rounding

The right solution for any requirement

For a generous edge rounding of up to 2 mm radius, the combination of several brushing systems proves to be extremely advantageous, not only because of the risk minimization of injuries, but also to improve corrosion protection. Our customers benefit from maximum flexibility, as they can choose the right units to meet a wide range of requirements. Our range of technologies enables precise and efficient processing on a wide variety of materials and surfaces, whether for damage-free edges or the processing of workpieces with particularly large edge roundings. Fast tool changes are essential, which is why our quick-change system enables tools to be changed in just a few minutes to avoid material carry-over.

Rounding edges Metal part

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FAQ
Questions about edge rounding

Edge rounding refers to the process of removing sharp edges from a workpiece to round or smooth them. This not only improves the aesthetic appearance, but can also increase safety and extend the life of the workpiece.

  • Safety: Rounded edges reduce the risk of injury from sharp edges.
  • Aesthetics: Smoothly rounded edges give the workpiece a high-quality appearance.
  • Durability: Rounding edges can help to extend the service life of the workpiece as it is less susceptible to damage.

Yes, depending on the type of sander and the workpiece, different techniques can be used, including moving the workpiece evenly along the edge, adjusting the sanding angle and using different pressure on the workpiece. It is important to use the correct technique for the particular workpiece and sander chosen.

The requirements for edge rounding are higher when coating: In practice, a rounding of 0.3 millimetres or more is often required for the paint to adhere properly and for the corrosion protection to be effective. Some standards even require 2.0 millimeters.

By rounding the sheet edge, cuts can be avoided, which is particularly important in working environments where people could come into contact with the components.

Depending on the intended use of the components, a small rounding of the sheet edge of 1/10 millimeter is often sufficient. This not only prevents cuts, but also prevents the edge from damaging a pneumatic hose or cable.
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