OUR TARGET ‘0’ BURR

BURR CORRECTION THEORY

• What is the Burr?

Excessive Burr (Small piece of material remained

attached to the edge of panel), More than 10% of Sheet
metal Thickness.
 SYSTEMATIC APPROCH FOR ACHIEVE ‘0’BURR

• After machining trim line check sheet.

• Trim line spotting data sheet.
• Made standard operating process.
• Employee training.
Trim line clearance sheet
After machining trim line check sheet.
Spotting data sheet
 Types of Burr and Chips
1. Excess clearance burr.
2. Tight clearance burr.
3. Vertical cutting burr.
4. Goose neck air cutting burr.
5. Double cutting burr – zero cutting burr.
6. Trim timing burr.
7. Less hardness burr.
8. Trim edge blunt burr.
9. Upper cutting damages the scrap – burr.
10. Cutting happening with upper cutter but needs to happen with cam cutter – burr.
11. Air cutting burr.
12. Less or no entry burr.
13. Excess trimming by upper cutter – burr.
14. No or insufficient shear angle in profile area – burr.
15. Locating lug double cutting burr.
16. Partial trimming burr.
17. Loose burr with panels.
18. Sharp corners of slot – burr.
19. One side rubbing burr.
20. Punch deflection burr.
21. Excess punch entry burr – say 10mm.
22. Less punch entry burr – say 2mm.
23. Back rubbing burr.
Burr Correction Theory
 Understand the type of burr.
 Select cutter: Upper or Lower.
 Do welding with proper hammering(Pinning).
 Start finishing with baby sander, 6mm grinder and 3mm grinder only.
 Ensure that welded area is not getting red hot while grinding.
 Always keep 3D up by 2mm, in case of Upper tool insert.
 Match 3D with reference of adjacent inserts in case of Lower tool.
 Keep maximum 0.3mm stock for 2D.
 Ensure squareness is maintained at 0.3mm stock and do stoning for 15 minutes.
 Load the die on press, clamp it and set relevant shut height.
 Apply clay to welded area – clay must be oil less – Dray clay, use general powder in case of wet clay.
 Take the shut height down till the clay gets trimmed.
 Remove the cut clay with knife or cutter.
 Start grinding with 3mm grinder only from bottom so that squareness will be maintained.
 Repeat the clay trimming 2-3 times and do grinding accordingly.
 Once you understand the clay trimming, remove the clay and apply thick Kometan to master.
 Take slider 0.1mm down, you will get impression on welded area, do not grind unless there is overlap.
 Go down by 0.1 mm, you will reach to entry point.
 Now you have to grind from bottom, do not touch the grinder to Kometan impression area.
 Go down – max 1mm entry – you will get some hard mark – do not worry.
 Go to shut height and then take total stroke of slide for 4 to 5 times.
 Do not apply grinder, remove all hard marks by stonning.
SOP
Check clearance through Check clearance through
Apply clay on trim line
masking tap masking tap

Take trim line immpresion Check clearance through kometan

Remove clay & check