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The Next Gen process is a novel process of electrolytic deburring and polishing for small, delicate and high precision components where burr extraction is in microscopic values. The utility could be extended to larger, less
delicate components to enhance existing deburring methods.
A highly discriminating inherently edge-seeking process,
which ensures burr removal with surfaces intact.
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The biodegradable nature of the residue renders the process totally environment friendly.
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The Next GEN Electrochemical Deburring consists of 50A and 300A, 500A, 750A Models which can be used for deburring of various components depending on the size.
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Based on the fundamental process of electrolysis, the component to be deburred is made the anode and a carefully dimensionally designed cathode is placed near the area
of deburring. The excessive material is dissolved in the electrolyte.
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An Ethylene glycol based solvent forms the electrolyte for the Next Gen process. The sticky electrolyte is
soluble in water and does not require additional and specialized safety procedures for venting, containment or rubber suites for operator safety. The Non-corrosive nature of the solvent operating at temperatures of 8-35 Deg C ensures that it is absolutely safe on skin, clothes or any other surface, unlike traditionally employed sodium chloride salt solution.
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The process is applicable universally to a wide range of metals including Steel, Stainless Steel, Aerospace alloys, Aluminium, Copper and Magnesium alloys. Stainless Steel and Copper emerging from the process have a highly reflective surface, while Aluminium appears matte to highly polished surfaces depending on the process parameters.
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The cleaned components are mounted on their respective
fixture based electrode. A high velocity electrolyte is passed through the fixture and a voltage is applied. This generates an electric field, which concentrates at the burrs (lightning rod effect) and a complex electrochemical reaction occurs disassociating the metal atoms from the burrs of the work piece. The disassociated atoms form metal hydroxide particles and can be filtered from the solution.
Most deburring is achieved in a time span of 30 seconds to 2 minutes. Micro burr remnants from a grinding process can be eliminated in shorter time spans with greater accuracy and minimizing defects. The process allows for deburring of multiple components simultaneously.
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A customized software application designed and developed in-house is employed by Elechem to estimate the rate of material removal. Online simulators are adapted in complex scenarios for greater precision. This methodology results in accurate and efficient deburring.
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The burr on the component with a thickness less than 0.2 mm and height 1.00 mm can be deburred to maintain a rounded edge of radius[R] 0.2 to 0.5 mm. This cycle can be completed with a time of 20 - 30 seconds. If the burr exceeds specification limits, then the rounding varies from a radius[R] of 0.5 to 1.5 mm and can take 60 - 100 seconds.
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