Case Study: Deflashing/Deburring machine for Mini Size Rubber Stopper, Plug; Deep Cold Technology;Cooling Process;

Case Study:Deflashing/Deburring machine Mini Size Rubber Stopper, Plug;​

DEEP - COLD TECHNOLOGY;

Cooling Process;

Why Choose Us;

Thanks to the deep and close relationships with our customers of hundreds of rubber manufacturers, who are constantly exploring technology for gains in productivity;

we strongly witness the importance of deflashing/deburring, a very important area for cost and quality controlling;

Thus the reason we add our new series line of Cryogenic Deflashing/Deburring Machines, our technical team has more than 10 years of experience in Deepaccumate more than; We aim to provide our customers with one-stop solutions no matter small, modest, or large scales of production;

Cryogenics is by far the most versatile, effective & economical option for deflashing rubber parts, a compact range of time-saving and quality-enhancing deflashing machines.

• A multi-material deflashing solution providing complete processing flexibility from one machine;

• A quality-enhancing method of deflashing;

• A system which increases productivity due to its exceptionally fast running speed;

• An automated cost-cutting method that dramatically decreases operational and labor costs;

• An environmentally-friendly device;

Advantages :

• Cryogenic deflashing provides various advantages over manual deflashing and other traditional deflashing methods.
• The process maintains part integrity and critical tolerances.
• Since it is a batch process, the price per piece is far less as many more parts can be processed in a given amount of time. That is to say, the cost per part is generally well below any alternative technique.
• Cryogenic deflashing extends mold life. Rather than replace or repair a mold (which typically involves downtime and high cost), the parts can be deflashed. This is typical of parts molded at the end of their product lifetime.
• The process is computer-controlled, therefore removing the human operator variable from the process.
• The process offers consistent results from lot to lot.
• Cryogenic deflashing is non-abrasive.
• Fully maintains tolerance (100%);
• Fully maintains surface quality (100%);
• Fully maintains material characteristics (100%);
• In 100% preservation of color;

Features:

A typical cryogenic deflashing machine consists of a stainless steel cabinet insulated with dense polyurethane foam; Located inside the cabinet are the blast chamber, the liquid nitrogen nozzle, and the opening for the throwing wheel.

INTER-CHINA Freeze Deflashing Machine with the unique features as following;

• Big size impeller for driving big capacity media one time;
• Continuous optimization of the inner hexagon structure, to achieve the optimal use of space; Thus, the consumption of liquid nitrogen is reduced and the efficiency is improved；
• High-quality NISSEI(Japan) gear motor, OMRON controller and PLC;
• User-friendly HMI, all parameters can be seen clearly and it is quite easy to operate；
• In-line flash and media separator ( 3 Layers );
• BASF PIR foam insulation stabilizes ambient temperature;
• Does not require a dryer；
• Long media life (approx. 300 cycles)；
• With electrically heated door seal strip;

VIDEO OF OUR CRYOGENIC DEFLASHING MACHINE ON YOUTUBE

Why should I use the Fully Automated trimming machine?

• Deflashing machine also known as deburring machine.
• Though this cryogenic deflashing technology has been in existence for over 50 years, its practical introduction happened about 20 years back. Its popularity has been on the rise in the last 15 years.
• This process uses liquid nitrogen, high-speed rotation, and media (shot blast) in varying combinations to remove the flash in a highly precise, economical, and practical manner.
• Compared to manual deflashing and other traditional deflashing methods.
• The fully automated process significantly decreases deflashing time, increasing production capacity;
• It also offers complete flexibility to multi-material processors.

When should I use the Freeze Trim Deflashing Machine:

• The INTER-CHINA Freeze Trim provides the user with complete processing flexibility, and it is ideal for those with large volume production, multiple part sizes and complexities (including those up to 250mm dia.), different materials, or when a high quality and pristine finish is paramount
• Example: Our Model SD-M/MT, with 120L basket capacity, daily ( 8 hours ) can complete the processing of 400~800kgs, which is equal to 30~100 workers manual job under the same working time.
• It’s totally amazing productivity.

How do the Freeze Trim/Cryogenic Deflashing Trimming Machines work?

• Molded parts are placed into a perforated stainless steel parts basket and then inserted into
• the blast chamber of the Freeze Trim and the basket is mechanically rotated to expose all parts to the blast media. Liquid nitrogen lowers the temperature (in some cases up to -140°C) while freezing the rubber to make it brittle. Because the burrs have a high surface area relative to their mass, they “freeze” very quickly and become brittle.
• The physical properties of the parts are not affected during the deflashing process.
• A unique high-speed impeller (up to 8,000rpm )directs and throws the polycarbonate media into the rotating basket and by traveling at high speed, the small pellets cleanly trim off the brittle flash leaving a high quality, flashless molding.
• The tumbling action— combined with the impact of the media— removes the burrs without damaging the part itself.
• After the process is complete, the parts are returned to room temperature.
• This cryogenic deburring leaves a clean part—with no dust or other residue remaining —with 100% burr removal.
• Parts that have thin flashes can be quickly and thoroughly cryogenic deflashed. Cryogenic
• Deflashing process is exceptionally good at removing the inner dimensional and complex flash in your products that cannot be removed by any other method.

• 

Temperature fluctuation in operation:

Owing to the fact that the temperature of the flash goes down quicker than the mold itself, deflashing can be done perfectly without damaging the product itself.

TA = Room temperature

TE = Embrittling temperature

TC = Set temperature in the barrel

t1 = Barrel operation starting time

t2 = Barrel operating stop time

Examples of the embrittling temperature
Material Name	Embrittling temperature ( ab ) °C
Natural Rubber ( NR )	- 60°C
Styrene Butadiene Rubber ( SBR )	- 50°C
Butadiene Rubber ( BR )	- 55°C
Acrylonitrile Butadiene Rubber ( NBR )	- 55°C
Butyl Rubber ( IIR )	- 60°C
Neoprene Rubber ( CR )	- 70°C
Silicone Rubber	-100°C
Urethane Rubber	- 70°C
FKM/FPM/VITON	- 75°C
PTFE/TEFLON	- 40°C
Polymer/Plastics Engineering/PE	- 45°C
Zinc alloy/ AL	ab - 40°C

Technical Parameters of Inter-China Cryogenic Deflashing Machine ;

Main Data	Model	SD-A/AT	SD-M/MT	SD-L/LT	SD-XL/XLT
	Maximum Basket Volume(Litres)	70	120	180	245
	Usable Volume (Litres)	30~45	50~75	80~115	120~155
	Total Power (kW)	5	7	9	13
	Refrigerant	Liquid Nitrogen (LN 2 )
	Operation Temp ( Degree)	50 ~ -130
	Media Type	Polycarbonate
	Power(voltage)	Three phase /AC380V±5%
	Frequency(HZ)	50/60	50/60	50/60	50/60
Main Structure & Components	Control Mode	BUTTON/HMI	BUTTON/HMI	BUTTON/HMI	PLC&HMI
		With alarm sensors to protect operators' safety
	IMPELLER UNIT	Standard	Standard	Standard	Double System
		Max Speed (rpm): ~7200
		Media Throwing Wheel Dia. (mm)
		250	300	300/350	300
	Sorting Device	Tunable Vibration Separator ( 3 Layers)
	Material of Body & Inner Parts	SUS304 /Thermal Insulation Material (PIR )/Soundproof cotton
Packing Infos	Equipment Weight(KG)	1000	1300	1450	1600
	Equipment Size(cm)	100*120*195	120*130*200	145*150*200	160*150*200

The average cycle time can range from 1.5 – 10 minutes depending on the number of parts per batch (which is, dependent on the size of your molded parts); flash thickness; wheel speed; and size of media used.

We have 4 standard models to meet different production demands;

The big capacity of Basket is unique, which dual bring with users a totally amazing productivity.

Order Options:

1. Capacity of Basket

2. Size of Impeller ( According to product size)

3. Color of Machine

4. Control Mode: Button or HMI

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For more details, please get in touch with us freely !!!

CONTACT INFOS

Person: Susanna

INTER-CHINA RUBBER MACHINERY CO., LTD.

www.rubbermachinery-china.com

Mob:+0086-13179487165

SKYPE: rubbercutting

Email: info@rubbermachinery-china.com

Case Study: Deflashing/Deburring machine for Mini Size Rubber Stopper, Plug; Deep Cold Technology;Cooling Process; Images