Deflashing Robots

Deflashing is a material removal application that involves the trimming of excess material from a molded, forged, or cast product. This excess material is often referred to as flash and occurs through the leakage of material between the two surfaces of the mold. Up until recent years, deflashing has been exclusively a manual process. However, it has long been known as being very error prone and difficult to perfect, causing manufacturers to turn to automation. Advancements in robotic technology has allowed for the expansion of robotic applications into more complex and diverse manufacturing processes, including deflashing. Robotic deflashing is revolutionizing casting industries with faster cycle times, increased efficiency, and improved production quality.

For automated deflashing applications industrial robots are integrated with a material removal EOAT. Pneumatic deburring tools and belt grinding tools are the two most common end-effectors utilized for robotic deflashing. Selecting the correct deflashing tool will depend upon the material being removed, the setting, and the robot. Deploying the right end-effector has been proven to allow for complete deflashing optimization with a reduction in cycle times by as much as 90%.

There are many material removal industrial robots that can be programmed and deployed for robotic deflashing. Some of the most popular ones include the FANUC R-2000ib/125L and the ABB IRB 4600. If your deflashing application will take place in a foundry, then you will want to select a robot that is IP rated for that environment. The FANUC M-710ic/50 has a standard IP rating of 67 on its wrist and J3 with a option for complete protection, making it fully protected from the harsh conditions of foundries. Severe dust and fumes commonly occur with deflashing processes, since materials are being grinded or cut away. Using an industrial robot that is protected from particle intrusion will prevent operation failures or the breakdown of the robot, ensuring productions run continuously.

Robotic deflashing can be used to remove many different material types, from plastics to metals. Robots allow for greater operation flexibility as they can be mounted either to the floor or overhead for deflashing applications. They also make it possible to work with larger workpieces or access to difficult to reach areas of a workpiece. The long reach of the Yaskawa Motoman MH50 provides an expanded work envelope, making it ideal for deflashing larger parts. Deflashing robots are also able to work at much faster rates, helping to increase operation productivity. A robot can deflash at a rate of four to five parts per minute. For those in high volume productions, a robotic workcell can be integrated with multiple deflashing robots for hyper productivity.

The integration of industrial robots for deflashing applications has significantly improved product quality for manufacturers. Manual deflashing has always been plagued by product inconsistencies causing poor quality. With manual deflashing it is impossible to replicate results causing each product to deviate from one another. With robotic deflashing, a ABB IRB 6640-185/2.80 is programmed with the application parameters, ensuring it operates with accuracy and precision to remove the same amount of flash from every cast or mold. It follows the exact path and specifications for each workpiece, ensuring uniform and quality products. As errors are eliminated production costs are reduced, allowing manufacturers to capture their ROI quickly.

Contact us by email mm@robotsdoneright.com or phone (440) 724-6568 today to discuss buying or selling a deflashing robot.