MOLD GRINDING POLISHING

MOLD GRINDING POLISHING

MOLD GRINDING POLISHING

Meister Finish ISO9001 Certified XEBEC produts are manufactured in a plant certified by ISO 9001, the international standard of quality control and assurance.

MOLD GRINDING POLISHINGG

Designed to finish dies and molds.

Meister Finish

Through the utilization of aerospace materials (alumina fiber filaments), cracking, and chipping have been eliminated. High polishing efficiency can be ensured. No clogging. Uniformly fine finishes can be achieved. Thanks to the braided structure of the rod type, high polishing efficiency is possible even with the side, of the tool, and there is no splitting of the tip. Suitable for fine deburring. Higher polishing efficiency can be achieved by using the Meister Finish with tools (electric, air, ultrasonic) Coarse grit type made of thick Alumina Fiber Filaments is ideal for removing EDM scales. Only XEBEC can manufacture it.

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Meister Finish Innovative technology Our engineers developed the world’s first ceramic fiber stones with aerospace materials (alumina fiber filaments) that utilize highly advanced chemical technologies.

High polishing efficiency can be ensured by the crystal structure of the alumina fiber filaments, which is optimal for polishing. Polishing efficiency and strength have been improved by the two way linear

MOLD GRINDING POLISHING

Features

structure, which prevents side-slipping. High accuracy of surfaces can be attained by the uniform fiber diameter. No dropping of abrasive grains that create linear scratches. Little heat generation that minimizes a workpiece alteration and the tool deterioration. The tip of a tool can be shaped in accordance with the shape of a workpiece.

(Rod Type) Innovative, braided structure of alumina fiber filaments. *No breakage during high speed rotation, No splitting of the tip. *Thanks to the braided structure, the tip or side of the tool can polish. Even boss holes of

0 0.3mm can be polished by shaping the tip of rod type.

Suitable for fine deburring and cross-hole deburring.

Usage

Ideal for precise polishing of free surfaces, free curves, ribs, bosses, etc.,

Applications

of various forming molds (especially plastic mold). Excellent polishing performance for material under HRC57. High polishing efficiency can be achieved without clogging, even for metals such as aluminum, copper, gun metal, etc., which clogs with Precise polishing of sub-gates

common abrasive stones. Can be used in narrow areas where common abrasivestones cannot be used because of breaking.

Precise polishing of ribs

Can be used on complex shapes where uniform finishing could not be

Higher polishing efficiency can be achieved by using the Meister Finish

previously attained.

with tools (electric, air, ultrasonic

Efficient EDM scales removal. XEBEC utilizes 50um alumina fiber filaments, the first in the industry. We developed the coarsest ceramic fiber stones (equivalent to #120)

For efficient use Use the tip at angle to the surface of a workpiece.

which have impressive efficiency with thick alimina fiber filaments.

Meister Finish Rod Type Structure Innovative, braided structure of alumina fiber filaments No breakage during high speed rotation!! Thanks to the braided structure, the side of the tool can polish! Polishing performance increases substantially when high-speed polishing becomes with a hand grinder!

Polishing and deburring using the tip or side of the tool is possible, thanks to the braided structure of alumina fiber filaments.

Can be shaped the tip of a tool in accordance with the shape of a workpiece.

Use the tip at an angle to the surface of a workpiece. Approximately 5~45 degrees is effective. Use with vibration tools (ultrasonic, air, electric etc.). Coolant will increase efficiency.

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Meister Finish

Stick Type

MOLD GRINDING POLISHINGG

Dimensions (mm) 0.3x4x100 0.4x4x100 0.5x4x100 0.5x4x150 0.5x6x100 0.5x6x150 0.5x10x100 0.5x10x150 0.8x4x100 0.8x4x150 0.8x6x100 0.8x6x150 0.8x10x100 0.8x10x150 1.0x1x100 1.0x2x100 1.0x4x100 1.0x4x150 1.0x6x100 1.0x6x150 1.0x8x100 1.0x8x150 1.0x10x100 1.0x10x150 1.5x1.5x100 1.5x4x100 1.5x4x150 1.5x6x100 1.5x6x150 1.5x10x100 1.5x10x150 2.0x2x100 2.0x4x100 2.0x4x150 2.0x6x100 2.0x6x150 2.0x10x100 2.0x10x150 3.0x4x100 3.0x4x150 3.0x6x100 3.0x6x150 3.0x10x100 3.0x10x150

Rod Type

Dimensions (mm) 1 x 50 1 x 100 1.5 x 50 1.5 x 100 2 x 50 2 x 100 2.34 x 50 2.34 x 100 3 x 50 3 x 100 3 x 150 6 x 50 6 x 100

Red equivalent to #1200 AR-0304M AR-0404M AR-0504M AR-0504L AR-0506M AR-0506L AR-0510M AR-0510L AR-0804M AR-0804L AR-0806M AR-0806L AR-0810M AR-0810L AR-1001M AR-1002M AR-1004M AR-1004L AR-1006M AR-1006L AR-1008M AR-1008L AR-1010M AR-1010L AR-15015M AR-1504M AR-1504L AR-1506M AR-1506L AR-1510M AR-1510L AR-2002M AR-2004M AR-2004L AR-2006M AR-2006L AR-2010M AR-2010L AR-3004M AR-3004L AR-3006M AR-3006L AR-3010M AR-3010L

White equivalent to #1000 AW-0304M AW-0404M AW-0504M AW-0504L AW-0506M AW-0506L AW-0510M AW-0510L AW-0804M AW-0804L AW-0806M AW-0806L AW-0810M AW-0810L AW-1001M AW-1002M AW-1004M AW-1004L AW-1006M AW-1006L AW-1008M AW-1008L AW-1010M AW-1010L AW-15015M AW-1504M AW-1504L AW-1506M AW-1506L AW-1510M AW-1510L AW-2002M AW-2004M AW-2004L AW-2006M AW-2006L AW-2010M AW-2010L AW-3004M AW-3004L AW-3006M AW-3006L AW-3010M AW-3010L

Blue equivalent to #800 AB-0304M AB-0404M AB-0504M AB-0504L AB-0506M AB-0506L AB-0510M AB-0510L AB-0804M AB-0804L AB-0806M AB-0806L AB-0810M AB-0810L AB-1001M AB-1002M AB-1004M AB-1004L AB-1006M AB-1006L AB-1008M AB-1008L AB-1010M AB-1010L AB-15015M AB-1504M AB-1504L AB-1506M AB-1506L AB-1510M AB-1510L AB-2002M AB-2004M AB-2004L AB-2006M AB-2006L AB-2010M AB-2010L AB-3004M AB-3004L AB-3006M AB-3006L AB-3010M AB-3010L

Black equivalent to #600 AP-0304M AP-0404M AP-0504M AP-0504L AP-0506M AP-0506L AP-0510M AP-0510L AP-0804M AP-0804L AP-0806M AP-0806L AP-0810M AP-0810L AP-1001M AP-1002M AP-1004M AP-1004L AP-1006M AP-1006L AP-1008M AP-1008L AP-1010M AP-1010L AP-15015M AP-1504M AP-1504L AP-1506M AP-1506L AP-1510M AP-1510L AP-2002M AP-2004M AP-2004L AP-2006M AP-2006L AP-2010M AP-2010L AP-3004M AP-3004L AP-3006M AP-3006L AP-3010M AP-3010L

Orange equivalent to #400 AO-0304M AO-0404M AO-0504M AO-0504L AO-0506M AO-0506L AO-0510M AO-0510L AO-0804M AO-0804L AO-0806M AO-0806L AO-0810M AO-0810L AO-1001M AO-1002M AO-1004M AO-1004L AO-1006M AO-1006L AO-1008M AO-1008L AO-1010M AO-1010L AO-15015M AO-1504M AO-1504L AO-1506M AO-1506L AO-1510M AO-1510L AO-2002M AO-2004M AO-2004L AO-2006M AO-2006L AO-2010M AO-2010L AO-3004M AO-3004L AO-3006M AO-3006L AO-3010M AO-3010L

Light Brown equivalent to #300 AL-0304M AL-0404M AL-0504M AL-0504L AL-0506M AL-0506L AL-0510M AL-0510L AL-0804M AL-0804L AL-0806M AL-0806L AL-0810M AL-0810L AL-1001M AL-1002M AL-1004M AL-1004L AL-1006M AL-1006L AL-1008M AL-1008L AL-1010M AL-1010L AL-15015M AL-1504M AL-1504L AL-1506M AL-1506L AL-1510M AL-1510L AL-2002M AL-2004M AL-2004L AL-2006M AL-2006L AL-2010M AL-2010L AL-3004M AL-3004L AL-3006M AL-3006L AL-3010M AL-3010L

Dark Brown equivalent to #220 AD-0304M AD-0404M AD-0504M AD-0504L AD-0506M AD-0506L AD-0510M AD-0510L AD-0804M AD-0804L AD-0806M AD-0806L AD-0810M AD-0810L AD-1001M AD-1002M AD-1004M AD-1004L AD-1006M AD-1006L AD-1008M AD-1008L AD-1010M AD-1010L AD-15015M AD-1504M AD-1504L AD-1506M AD-1506L AD-1510M AD-1510L AD-2002M AD-2004M AD-2004L AD-2006M AD-2006L AD-2010M AD-2010L AD-3004M AD-3004L AD-3006M AD-3006L AD-3010M AD-3010L

Red equivalent to #1200 APR-10S PR-10M PR-15S PR-15M PR-20S PR-20M PR-234S PR-234M PR-30S PR-30M PR-30L

White equivalent to #1000 PW-10S PW-10M PW-15S PW-15M PW-20S PW-20M PW-234S PW-234M PW-30S PW-30M PW-30L

Blue equivalent to #800 PB-10S PB-10M PB-15S PB-15M PB-20S PB-20M PB-234S PB-234M PB-30S PB-30M PB-30L

Black equivalent to #600 PP-10S PP-10M PP-15S PP-15M PP-20S PP-20M PP-234S PP-234M PP-30S PP-30M PP-30L

Orange equivalent to #400 PO-10S PO-10M PO-15S PO-15M PO-20S PO-20M PO-234S PO-234M PO-30S PO-30M PO-30L

Light Brown equivalent to #300 PL-10S PL-10M PL-15S PL-15M PL-20S PL-20M PL-234S PL-234M PL-30S PL-30M PL-30L

Grey equivalent to #220 PM-10S PM-10M PM-15S PM-15M PM-20S PM-20M PM-234S PM-234M PM-30S PM-30M PM-30L PM-60S PM-60M

-

-

Meister Finish Rod Type Structure [Alumina fiber filaments structure] The bundles of alumina fiber filaments cross and set in each other.

-

-

-

-

Violet equivalent to #120 AV-1002M AV-1004M AV-1004L AV-1006M AV-1006L AV-1008M AV-1008L AV-1010M AV-1010L AV-1504M AV-1504L AV-1506M AV-1506L AV-1510M AV-1510L AV-2004M AV-2004L AV-2006M AV-2006L AV-2010M AV-2010L AV-3004M AV-3004L AV-3006M AV-3006L AV-3010M AV-3010L

Meister Finish rod type is braided structure of alumina fiber filaments. (Refer to inside text) The structure below 2mm or equivalent to #220(Grey) is as follows.

[Effect] Not easy to break or tear, and longer tool life. The tip or side of the tool can polish. Made of the plate as shown above photo.

Usage precautions Before using a vibration tool or a hand grinder, carefully read the usage precautions and respective manuals. When using rod type with a hand grinder, use at less than the maximum rpm of 30,000 and less than 50mm in length. Always wear protective glasses, gloves, and masks when working.

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XEBEC Heat - Resistance A Definite Difference! ISO9001 Certified XEBEC produts are manufactured in a plant certified by ISO 9001, the international standard of quality control and assurance.

XEBEC Heat-Resistant Ceramic Abrasives

MOLD GRINDING POLISHING

Patent Pending

Excellent Heat Resistance! Doesn’t Soften! Outstanding efficiency! XEBEC has successfully increased the resisitance temperature from 100 C to 200 C in its Heat-Resistant Ceramic Abrasives. Adding to the same performance of the Meister Finish (doesn’t break, doesn’t crack, excellent sharpness), their durability has been enhanced for prolonged use with Ultrasonic tool. Ideal for removing EDMscales. Can be used to polish deep slits of ribs, at full length.

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XEBEC Heat - Resistance Lineup

MOLD GRINDING POLISHINGG

Grit

Equivalent to #1200

Equivalent to #800

Equivalent to #220

Equivalent to #120

color

Red

Blue

Dark Brown

Violet

Thickness(mm)

Width(mm)

Length(mm)

Code No.

1

4

100

HR-1004M

1

6

100

HR-1006M

1

10

100

HR-1010M

2

4

100

HR-2004M

2

6

100

HR-2006M

2 1

10 4

100 100

HR-2010M HB-1004M

1

6

100

HB-1006M

1

10

100

HB-1010M

2

4

100

HB-2004M

2

6

100

HB-2006M

2 1

10 4

100 100

HB-2010M HD-1004M

1

6

100

HD-1006M

1

10

100

HD-1010M

2

4

100

HD-2004M

2

6

100

HD-2006M

2 1

10 4

100 100

HD-2010M HV-1004M

1

6

100

HV-1006M

1

10

100

HV-1010M

2

4

100

HV-2004M

2

6

100

HV-2006M

2

10

100

HV-2010M

Precautions in use [When Using with an Ultrasonic Tools] Check the appropriate output. The tool may break or generate heat when the output is too large. Check the appropriate length. If the length is inappropriate, the tool may not oscillate, or concentrated output may result in heat generation. Clamp securely. Poor clamping may concentrate putput, resulting in excessive heat generation. Polishing performance may vary depending on the structure and method of the clamp in use; read carefully the instruction manual of your ultrasonic tool.

[Protection] Wear protective eyeglasses, gloves and mask duting use.

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XEBEC Diamond For polishing hardened steel and cemented carbide. ISO9001 Certified XEBEC produts are manufactured in a plant certified by ISO 9001, the international standard of quality control and assurance.

MOLD GRINDING POLISHING

XEBEC Diamond Patent Pending

Please put to test the accurate”sharpness”, “responsiveness”, and”surface stability”.

Features of the XEBEC Diamond Effeciently and cleanly polishes materials harder than HRC57 such as cemented carbide and hardened steel (SKD, DC, STAVAX, HPM, ASP, etc) Both the Stick and the Rod types can be used to polish by the tip or the side Can be formed into desired shape, such as a thinner tip Suitable for removing EDM scales, polishing ribs and deburring from edges and corners Far more efficient than electroplated diamond files, hand lappers, diamond pastes and diamond powders While an electroplated diamond file has diamonds only on its surface, the XEBEC Diamond has diamonds embedded in layers, enabling it to be used to the end without losing its sharpness. Also lasts longer than an electroplated diamond file. Can polish efficiently wet or dry Can be used even more efficiently when attached to tools (electric, air, or ultrasonic) Rod type can be attached to rotary tools (max. 30,000 r.p.m.)

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XEBEC Diamond XEBEC Diamond Polishing Performance Data Work Polishing Surface

Cemented Carbide

MOLD GRINDING POLISHINGG

1. Polishing Performance by the Side Comparison of Polishing Performance by the Side (Comparison with electroplated diamond file)

Ra

Surface Roughness Rmax

Ra

Surface Roughness Rmax

V10 (HRA90) WEDM Surface

SKD11 (HRC57)

Hardened Steel

EDM Surface (HRC67)

Surface Roughness Ra Rmax DC53 (HRC61) EDM Surface (HRC69)

The above ( indicate hardness.

)

polishing conditions

XEBEC Diamond #200 (1mmt ) electroplated diamond file #200 polishing method : air tool, by the side, dry : 250g load : 5kgf/cm 2 (lap rounds 17,000r.p.m.) air pressure polishing area : 30mmX15mm

Explanarion of the Graph The graphs represent comparisons of polishing performance data between XEBEC Diamond and an electroplate diamond file, both #200, using both on its side. Polishing efficiency is very high, and the surfaces are finished in a short time. The XEBEC Diamond shows maximum roughness (R max) to be very low, and that the surface is very even. Though the XEBEC Diamond may have the same grid, it can give surfaces a finer finish, thus enabling it to shorten the work which took far longer by electroplated diamond file.

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XEBEC Diamond XEBEC Diamond Polishing Performance Data 2. Polishing Performance by the Side XEBEC Diamond

Polishing Surface

Polishing Performances of #200 / #400 / #800

Cemented Carbide

Ra

Surface Roughness

Rmax

Ra

Surface Roughness

Rmax

Ra

Surface Roughness

Rmax

V10 (HRA90)

MOLD GRINDING POLISHING

Work

WEDM Surface

SKD11 (HRC57)

Hardened Steel

EDM Surface (HRC67)

DC53 (HRC61) EDM Surface (HRC69)

The above ( indicate hardness.

)

polishing conditions

XEBEC Diamond #200 (1mm t ) XEBEC Diamond #400 (1mm t ) XEBEC Diamond #800 (1mm t ) polishing method : air tool, by the side, dry : 700g load : 5kgf/cm 2 (lap rounds 17,000r.p.m.) air pressure polishing area : 30mmX15mm

Explanarion of the Graph The graphs for Cemented Carbide show the surface smoothness of a wirecut surface by using XEBEC Diamond #400 for 5 minutes, then #800 afterwards. The graphs for Hardened Steel show the surface smoothness of an EDM surface by using XEBEC Diamond #200 for the first 20 minutes, than #800 afterwards. It takes a very short time to achieve high surface smoothness on both cemented carbide and hardened steel. With the above combination, R max=1um can be achieved in a short time.

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XEBEC Diamond XEBEC Diamond Lineup MOLD GRINDING POLISHINGG

1. Stick type Grit (color)

#200 (black)

2. Rod type

Dimensions(mm)

Code No.

1 X 4 X 100

DM1004M

1 X 6 X 100

DM1006M

1 X 10 X 100

DM1010M

Grit (color)

Dimensions(mm)

#400 (bluegreen)

Code No.

0 3 X 50

PDF30S

0 3 X 100

PDF30M

Usage #400 (bluegreen)

#800 (gray)

1 X 4 X 100

DF1004M

1 X 6 X 100

DF1006M

1 X 10 X 100

DF1010M

1 X 4 X 100

DS1004M

1 X 6 X 100

DS1006M

1 X 10 X 100

DS1010M

Ideal for polishing extremely hard die and mold (especially materials harder than HRC57). Usage can be specified for: Surface polishing Finishing ribs after EDM Finishing gates after EDM Finishing and deburring in carners Finishing and deburring in edges Chamfering corners (to be rounded or chamfered)

For the Most Efficient Use... Coolant The XEBEC Diamond can be used either dry or wet. Coolant will increase efficiency. Forming (Shaping the tip of a tool in accordance with the shape of a workpiece.) / Dressing For easy and perfect forming / dressing, use an electrodeposited diamond stone. Do cutting same way. For easy and perfect forming / dressing, press a tool rotating in a hand grinder onto an electrodeposited diamond stone. Do cutting same way.

Precautions in use When Using with an ultrasonic tool Please check the appropriate output. The tool may break or generate heat when the outout is too large. Please check the appropriate length. On an inapproproate length, the tool may not oscillate, or concentrated output may result in heat generation. A bad clamp may concentrate output, resulting in heat generation. Polishing capabilities may vary depending on the structure and method of the clamp in use; please read carefully the instructions of your supersonic tool.

When Using with a hand grinder Please use below the maximum 30,000rpm. Please use below 50mm full length. (If full length is more than 50mm; make sure to cut it below 50mm.)

When Using with a hand grinder Please wear protective eyeglasses, gloves and mask during use.

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XEBEC - Pencil type R

Meister Finish Pencil Type MOLD GRINDING POLISHING

Deburring - Polishing in Narrow area Feature Meister Finish (Not easy to broken, give good surace finish) use with drawing pencil. Can be work with steel HRC57 Good working in narrow area.

Thin-Small (square) 0.5mm, 0.9mm

Meister Finish / Pencil type Line up Item Code

Grit

Color

3PACK-AR-0505S

#1200 (Red)

Red

#800 (Blue)

Blue

3PACK-AR-0909S 3PACK-AB-0505S 3PACK-AB-0909S

TxWxL (mm)

PC/pack pencil Holder

0.5x0.5x50

3

PCL-5

0.9x0.9x50

3

PCL-9

0.5x0.5x50

3

PCL-5

0.9x0.9x50

3

PCL-9

XEBEC Pencil Holder Line up Item Code

size

Pencil

PCL-5

O 0.7mm(0.5mm )

AR-0505S

AB-0505S

PCL-9

O 1.3mm(0.9mm )

AR-0909S

AB-0909S

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XEBEC - Soft Ceramic Stone Soft Ceramic Fiber Stones

Made in JAPAN

MOLD GRINDING POLISHINGG

For ANYBODY! QUICK, BEAUTIFUL and EASY!

Innovation of : Removing scratches! Makes shiny surface! Deburring precision and fine burrs! Polishing copper EDM electrode! Stick type and Rod type available 䋪These soft ceramic stones are for hand use.䇭onlyDO NOT USE with any machines 䋪Usage under excessive pressure may cause breakage of the stone.

Features -Suitable for shining Die/Mould of hardness up to HRC 50. -Does not damage or make scratches on workpiece thanks to its rubber elasticity. -Easy to shape the tip ( such with fine sand-paper.) -Deburrs without rounding the edges even by tracing the target area. -Makes shiny surface. -Stable cutting and finishing ability is sustained thanks to the continuous alumina fiber filaments used in it.

ERASE scratches! Before

Only in 10 sec!

Applications

After

-Removing scratches of finished products. -Removing cutter marks on copper EDM electrode and polishing and shining. -Ideal for shining Aluminummade Die/Mold. -Ideal for deburringcopper EDM electrode. -Modifying swells and shining bosses and spurs with rod type..

Line up

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Product Type

Product Code

Equivalent Grit

Dimensions:H xWxL(mm)

Stick Type

BS-2006M

#1200

2x6x100

Rod Type

PBS-30M

#1200

ɉ3x100

XEBEC - Soft Ceramic Stone Comparisons with conventional tools Possible replacements : Elastic stone, Paste, Buffing

Long tool life, no scratches, soft touch to workpiece.

MOLD GRINDING POLISHING

Advantages

87

DEBURRING TOOL

DEBURRING TOOL

ISO9001 Certified XEBEC products are manufactured in a plant certified by ISO9001,

Cutting Fiber (Cup Brush)

the internationnal standard of quality control and assurance.

Patent Pending

DEBURRING TOOL

Ideal for automated fine deburring and surface finishing.

Features Suitable for use on machining centers, robots, custom machines and drilling machines-easy to automate. Superior grinding performance thanks to the self-sharprning action of the cutting edge of the Fine Alumina Fiber rod tips. The continuous cutting edge provides stable grinding performance. Consistently superior grinding performance can be achieved by establishing suitable processing conditions. (cutting depth and rpm) Can deburr and finish edges simultaneously. Can improve surface roughness in a shorter time, thus shortening the finishing process. Ideal for fine deburring and surface finishing of automotive parts, aircraft parts and machine parts.

189

Fine Alumina Fiber Rods and Structure 1 Fine Alumina Fiber Rod in the XEBEC Cutting Fiber Has 1,000 Cutting Edges.

DEBURRING TOOL



One fine alumina fiber rod is made by binding together 1,000 alumina fiber filaments (ALF), each only several um in diameter. The tips on each of the 1,000 ALFs are the cutting edges. The self-sharpening action of the cutting edge on the fine alumina fiber rod tips provides superior grinding performance. Continuous cutting edges provide a stable and continuous grinding performance.

Grinding Performance Grinding Performance Comparison with Abrasive Nylon Brush and Brsaa Brush





(Note) * Abrasive Nylon Brush means Nylon brush with monofilaments including abrasive grains. * Legends show [Depth of cut (mm) and Revolutions (rpm)]. * Work Reduction can be controlled through processing conditions (Depth of cut and Revolutions). * The above data are comparisons based on setting up the most appropriate processing conditions for each tool. * Because this test was to examine the grinding performance on a flat work, the depth of cut is relatively large.

190

Applications This is “The Sharpness” of XEBEC Cutting Fiber Fine Deburring after Miniscule Diameter Bore (Drill) Processing Workpiece Processing Content

PGA Die

Material

NAK55

Fine Deburring after O 0.5mm bore (drill) processing Before Deburring

After Deburring

DEBURRING TOOL

Other Applications : Injector Body, O 0.1mm jet nozzeles, etc.

Fine Deburring after Gear Cutting Workpiece Processing Content

Ring-Shaped Internal Gear Material

S45C

Fine Deburring gear portions of the ring after Gear Cutting Before Deburring

After Deburring

Fine Deburring after Surface Grinding Workpiece Processing Content

Plate

Material

S45C

Fine Deburring the edges of the cut area on the plate Before Deburring

After Deburring

191

Applications Cutting Fiber with Higher Grinding Power A31(Blue) Work piece Gear Material Steel Tool:A31-CB25M Parameters RPM3500min-1 Feed2500mm/min Depth of cut1mm

Burrs

DEBURRING TOOL

0.2mm

After

Before Work piece Blade Material : Titanium Tool:A31-CB40M Parameters RPM2000min-1 Feed500mm/min Depth of cut1mm

Steps of ball end milling

After

Before

Target burr size and material Burr size Thickness

high

Burr thickness 0.1 mm (not height) = If the burr can be removed by your finger nail, it is about 0.1 mm thickness

Recommended Initial Parameters for Deburring edges

1. Depth of cut (Grinding Load) - after end mill (vertical burrs): 0.5 mm - after face mill (horizontal burrs): 1.0 mm

2. Revolutions

Target Burr size

80 % of the maximum rpm

Pink (A13) : 0.05 mm. Red (A11) : 0.1 mm. White (A21) : 0.1 mm. Blue (A31) : 0.15-0.2 mm.

Materials Any materials under HRC(Rockwell Code)57 SC, SS, SUS, Ti, FC, FCD.......

15mm

25mm

40mm

60mm

Max. RPM

10,000

6mm

6,000

5,000

3,000

2,000

100mm 1,200

Initial RPM

8,000

4,800

4,000

2,400

1,600

960

3. Feed Rate 2,400mm/min

How to select Cutting Fiber Choose a brush by the material and cutting process of the work piece

4. Fine Alumina Fiber Rods exposure from sleeve 100,

60,

40,

25: 15mm 15: 10mm 06: 5mm

5. Dry / Wet processing (1) Deburring: The brush can be used for both dry and wet processing (2) Surface grinding: Refer to the matrix below

192

XEBEC Cutting Fiber Lineup Brush

Type

Alumina Fiber Rod(color)

Diameter 100mm 60mm 40mm 25mm 15mm 6mm 5mm 100mm 60mm 40mm 25mm 15mm 6mm 5mm 100mm 60mm 40mm 25mm 15mm 6mm 15mm 6mm 3mm

A11 (Red) A11 (Red) A11 (Red) A11 (Red) A11 (Red) A11 (Red) A11 (Red) A21 (White) A21 (White) A21 (White) A21 (White) A21 (White) A21 (White) A11 (White) A31 (Blue) A31 (Blue) A31 (Blue) A31 (Blue) A31 (Blue) A31 (Blue) A13 (Pink) A13 (Pink) A13 (Pink)

Alumina Fiber Rod Length

Corresponding Sleeve (Product Code)

75mm 75mm 75mm 75mm 50mm 30mm 20mm 75mm 75mm 75mm 75mm 50mm 30mm 20mm 75mm 75mm 75mm 75mm 50mm 30mm 50mm 30mm 30mm

S100M S60M S40M S25M S15M S06M 3mm shank withoutsleeve

S100M S60M S40M S25M S15M S06M 3mm shank withoutsleeve

S100M S60M S40M S25M S15M S06M S15M S06M

DEBURRING TOOL

Cup Cup Cup Cup Cup Cup End Cup Cup Cup Cup Cup Cup End Cup Cup Cup Cup Cup Cup Cup Cup End

Product Code A11-CB100M A11-CB60M A11-CB40M A11-CB25M A11-CB15M A11-CB06M A11-EB06M A21-CB100M A21-CB60M A21-CB40M A21-CB25M A21-CB15M A21-CB06M A21-EB06M A31-CB100M A31-CB60M A31-CB40M A31-CB25M A31-CB15M A31-CB06M A13-CB15M A13-CB06M A13-EB03M

3mm shank withoutsleeve

Sleeve Cutting fiber Diameter

100mm M 60mm M 40mm M 25mm M 15mm M 6mm M . ( ... )

Product Code S100M S60M S40M S25M S15M S06M

Axis Core Diameter

Sleeve External Diameter

16mm 12mm 8mm 8mm 6mm 6mm

Length of all axes is 30mm.

110mm 65mm 45mm 30mm 18mm 10mm . .. .

Full Length (incl. Axis)

Axis Length

162mm 150mm 140mm 140mm 90mm 70mm

40mm 35mm 30mm 30mm 30mm 30mm

Corresponding Brush (Product Code)

A11/A21/A31-CB100M A11/A21/A31-CB60M A11/A21/A31-CB40M A11/A21/A31-CB25M A11/A21/A31/A13-CB15M A11/A21/A31/A13-CB06M

Specifications may be subject to change without notice.

[Maximum Revolutions] Please use within the range of maximum revolutions ( 100: under 1,200rpm, 60: under 2,000rpm, 6: under 10,000rpm) Usage over the maximum revolutions is dangerous because it may result in breakage.

40: under 3,000rpm,

25: under 5,000rpm,

15: under 6,000rpm,

[Depth of cut, Grinding Load] Usage under excessive depth of cut or grind load may not result in the desired, results, as well as shortened brush life caused by pronounced wear and breakage of the fine alumina fiber rods. Processing is the most effective using the tips of the fine alumina fiber rod. For the depth of cut, use 0.5mm to 1.0mm as a guideline, up to 1.5mm.

[Fine Alumina Fiber Rods Projection Adjustment] Attaching a sleeve (an external cylinder) to the perimeter of the brush allows for the projection of the fine alumina fiber rods to be asjusted for fine-tuning flexibility and trackability. Longer projection increases trackability and flexibility, while shorter projection decreases them. However, please keep projection range under 20mm for 100, 60, 40 and 25, under 15mm for 15, and under 10mm for 6.Usage beyond the projection range may result in damage to the brush.

[Bristle Length] With usage over time, the overall length of the fine alumina fiber rods (bristle length) may shorten, result in more grinding power but less easy to fit, please adjust the grind and fit by dropping the revolutions and depth of cut.

[Dry/Wet Processing] The brush can be used for both dry and wet processing, but please use a dust collecting device to collect the dust that is produced during dry processing.

[For Protective Equipment] Always wear protective goggles, gloves and masks when operating the tool. Wear long sleeves, tight cuffs, and clothing to minimize skin exposure.

[Beware of Grinding Powder] Grinding powder and burrs may scatter within an area around the work as the brush revolves; please stay clear of this area. When using on high-precision processing equipment, the abrasive powder may adversely affect the sliding parts, so please be sure to collet any dust and keep clean the equipment.

[Caution for area around work] The area around your work is hazardous due to flying pieces of fiber rods from the brush and grinding poeder. Please enclose your work area to prevent other people from entering, or have the surrounding people wear protection as well.

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ISO9001 Certified XEBEC products are manufactured in a plant certified by ISO9001,

Cutting Fiber (End Brush)

the internationnal standard of quality control and assurance.

Patent Pending

Hand Tool Brush DEBURRING TOOL

Please use below the maximum revolutions of 12,000 rpm.

EDM Scale Removal from Molds

g Minute deburring

Features The tips of the fine alumina fiber rods have superior grinding power Can greatly improve surface smoothness in a short time Soft to the touch, prevents undulations in the work Less clogging with the self-sharpening action of the fiber rod tips Can be used in dry or wet processing

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Main Uses EDM Scale Removal from Molds Modifying molds Deburring after forming of precision parts Deburring after machine processing of precision parts Surface finishing (removing post-processing marks and scales)

Grinding Performance This is a comparison in grinding performance with diamond-ingrained abrasive nylon brush (#400)

. .. . XEBEC Cutting Fiber improves . .. . XEBEC Cutting Fiber has superior

grinding ability.

DEBURRING TOOL

surface smoothness in a short time.

A11 : Easy to fit, suitable for minute deburring. A21 : More rigid than A11, superior grinding efficiency.

Line up Type

Product Code

Fine Alumina Fiber Rod (color)

End End

A11-EB06M A21-EB06M

A11 (Red) A21 (White)

Diameter

6mm 6mm

Fine Alumina Fiber Rod Length

20mm 20mm

Axis Core Diameter

3mm 3mm

. .. . We are planning more additions and expansions to our lineup, Please visit our homepage for details.

[Pre-operation Inspections] Conduct a test run for one minute before starting operation, and three minutes after changing the brush, to check for abnormalities, such as vibrations, or looseness of the brush axis joint. Even if there are no abnormalities during the test run, if you notice anything unusual such as vibrations during usage, please stop the operation immediately; breakage, deformation, or damage to such parts as the brush fiber rods and the axis.

[Maximum Revolutions] Please use below the maximum revolutions of 12,000 rpm. Usage above the maximum may be dangerous because it may result in breakage to such parts as the brush fiber rods and the axis.

[Grinding Load, Depth of cut] Usage with an excessive load (depth of cut) may not only give less than optimal results, but may also lead to breakage and scattering of fine alumina wire rods. They are especially prone to occur when processing edges and uneven areas; it is therefore necessary to process with low enough revolutions and a lighter load.

[Polishing Flat Surfaces] Attach to a hand tool, and apply brush to work surface at an approximate 45 degrees angle. Apply as constant a load as possible with the brush to the work, and keep the depth of cut to a minimum (under 1mm).

[Protection] Please always wear protective glasses, gloves, and masks when working. Also, wear long sleeves, and close all cuffs and hems of your outerwear so that your skin is not exposed.

[Beware of Grinding Powder] Grinding powder and burrs may scatter within the area around the work as the brush revolves; please use a dust collecting device to collect the dust that is produced during dry processing.

[Caution to Your Surroundings] The area around your work is hazardous due to flying pieces of fiber rods from the brush and grinding powfer; please enclose your working area to prevent other people from entering, or have the surrounding people wear protection as well.

[Polishing Edges and Deburring Uneven Areas] When polishing edges and deburring uneven areas. please work with lower revolutions and a lighter load, Also, please do not apply excessive pressure on the edges with the sides of the fiber rods.

[Bristle Length] With usage over time, the overall length of the fine alumina fiber rods (bristle length) may shorten, resulting in more grinding power but less easy to fit; please adjust the grind and fit by decreasing the revolutions and load (depth of cut).

[Truing / Dressing] Press the tip of the rotating brush against some polishing paper stuck onto a board in order to adjust the form of the brush. Please do the same for the dressing as well.

[Dry / Wet Processing] XEBEC Cutting Fiber can be used for both dry and wet processing, Please use a dust collecting device to collect any dust produced during dry processing.

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Floating Holder is an optional tool for Cutting Fiber to stabilize the cutting load. DEBURRING TOOL

Product Code:

FH-ST12

[Features] Extend Tool Life! Reduce the amount of tool wear so as to stabilize processing conditions.

Reduce Process Control! Prolongs time to adjust brush exposure from sleeve and cutting depth due to tool wear.

Improve Quality! Delivers stable edge quality by adjusting for hcanges in cutting amount due to tool wear.

Ideal for Mass Productions!!! The tool holder floats by the action of the spring inside the holder, thus assuring stable processing under load control! Changing spring load is possible depending on materials and target quality!! (incl. standard with low and high springs)

Ideal to be used in CNC machines for mass productions and can also be used in drill press to stabilize the cutting load! ~with various machines~ Machining Center Custom Machine NC Lathe Drill Press Other CNC machines Can be used with collett chuck and drill chuck.

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Drill Press

CNC Machine

[Specification]

Product Code

FH-ST12

Spring Load Spring Type Stroke 0 mm

Stroke 6 mm

Low Load High Load

Precautions in Use

DEBURRING TOOL

Standard

Operator Safety Measures

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ISO 9001 Certified

DEBURRING TOOL

Cross-Hole Deburring Tool ool

Only XEBEC’s alumina fiber has created! t d! Select XEBEC for fine deburring of cross-holes 3 mm to 20 mm in diameter!!

Ceramic Stone Type

Patent Pending

Easy-to-use with hand grinder. Tool head is made of alumina fiber abrasive stone. Cutting edges are exposed over the entire surface. Efficient removal of fine burrs where the base thickness is 0.2 mm or less after machine processing. Ideal for point processing of cross-hole fine deburring. Flexible shaft for soft contact with the workpiece. Also use in a machining center, NC lathe, robot, etc.

Alumina Fiber Rod Type Optimal for the automation of cross-hole deburring. Powerful tip grinding with “XEBEC Cutting Fiber” for rods made of alumina fiber abrasive stone. Burrs are accurately removed without damaging periphery of the cross-hole and without breaking the edge pattern. Centrifugal force generated by rotation effiiciently removes cross-hole fine burrs in cylinders. Precision removal of all fine burrs where the base thickness is 0.1 mm or less after machine processing. Also can be used for polishing or scale removal on inner wall surfaces of cylinders.

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Ceramic Stone Type Material and Structure

Material

Structure

DEBURRING TOOL

The “Meister Finish” is an abrasive stone made of XEBEC alumina fibers which have the optimum crystal structure for grinding. Shaped into spherical and columna configurations, the stone surface has multitude of fiber cutting edges providing superior grinding force and performance. The self-sharpening action of the cutting edge on the fine alumina fiber rod tips provides superior grinding ability. Continuous cutting edges provide a stable and continuous grinding performance. The shaft flexibility allows soft contact with the workpiece.

Deburring Performance “Point processing” or “Contouring” efficiently removes only fine cross-hole burrs. Comparison of deburring finish of cross-hole burrs generated in Before Deburring

Material : S45C

3.5 mm drill processing

After Deburring (Comparison by same processing condition)

Tool rpm:5000rpm

Processing time: 1sec Bore diameter in primary processing:

5mm Bore diameter in secondary processing: 3.5mm

Usage, Applications Point processing (Insert from primary processing hole) By choosing a head that is slightly larger than the bore of vross-hole, burrs can be e efficiently removed.

Contouring (Insert from secondary processing hole) Automated deburring application on a machining center. General Machine Compenent (Hydraulic component) / Material: SUS

Workpiece

Primary hole 20mm dia. Secondary hole 5.3mm dia. Pre-Processing: Drilling

Tool Used Description Conditions Effectiveness

CH-PM-5B (Insert from secondary processing hole) After drilling, contour the bore edge to remove burrs. Tool Revolutions:5,000rpm, Depth of cut: 0.5mm, Feed rate: 300mm/min Manual processing with a cutter resulted in inefficiency

Before and unstable finishing quality.

Full automation on a machining center was possible

After and finishing quality became stable.

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Alumina Fiber Rod Type Material

Material and Structure

DEBURRING TOOL

Using the technology of “XEBEC Cutting Fiber”, which is the world’s first fiber rod made from ceramic abrasive stone, we have produced a colunbar fiber rod. One alumina fiber rod is made by binding together 1,000 alumina fiber filaments which have optimum crystal structure for grinding, each 10um in diameter. The tip has 1,000 high-density cutting edges. The self-sharpening action of the cutting edge on the fine alumina fiber rod tips provides superior grinding ability. Continuous cutting edges provides provide a stable and continuous grinding performance.

Structure Deburring Performance

This rigid fiber rod with high grinding capability is then shaped into a flexible brush to allow soft contact with the workpiece.

Burrs are accurately removed without damaging periphery of the cross-hole and without breaking the edge pattern. Deburring of cross-hole burrs generated in Before Deburring

After Deburring

4 mm drill processing Processing method; processing from both sides of the primary processing hole.

Profile curve of arrowed portion in photograph

Material: S45C Applied tool: CH-A12-5M Bore diameter in primary processing: 10mm Bore diameter in secondary processing: 4mm Tool rpm: 10,000rpm Feed rate: 5mm/sec

Tip of rod effectively removes burrs under rotational / centrifugal force. First insert a tip of the tool into the cylinder, and then switch “ON”. Step1 insert the tool into hole before switching “ON”. Step2 insert the tool into hole before switching “ON”. Step3 Work the brush back and force within the workpiece. Step4 Stop tool rotation before withdrawing tool from hole.

For effective deburring, repeat steps 1 to 4 from the opposite side of the workpiece. *As burrs are removed under rotational / centrifugal force, tool revolutions need more than 8,000rpm.

Usage, Applications

Tool revolutions need more 8,000 rpm

Automated deburring application with a custom machine General Machine Compenent (Valve Case) / Material: Aluminum Alloy

Workpiece

Primary hole 5mm dia. Secondary hole 2mm dia. Pre-Processing: Drilling

Tool Used Description Conditions Effectiveness

CH-A12-3M (Insert from secondary processing hole) After drilling, minimize the burr size with a drill and to deburr Tool Revolutions:10,000rpm, Feed rate: 300mm/min Long manual processing time with a cutter

Before and left scratches on the finishing surface.

Work efficiency improved with automated deburring

After by a custom machine and no more burrs left.

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Product Lineup Ceramic Stone Type Target Bore Diameter in primary Processing

Head Shape

3mm 3x3mm 4mm 4x4mm 5mm 5x5mm 6mm

Sphere Column Sphere Column Sphere Column Sphere

Over 3mm Over 4mm Over 5mm Over 6mm

Product Code Gray Orange Blue Equivalent to #220 Equivalent to #400 Equivalent to #800

CH-PM-3B CH-PM-3R CH-PM-4B CH-PM-4R CH-PM-5B

CH-PO-3B CH-PO-3R CH-PO-4B CH-PO-4R CH-PO-5B

CH-PB-3B CH-PB-3R CH-PB-4B CH-PB-4R CH-PB-5B

CH-PM-5R CH-PM-6B

CH-PO-5R CH-PO-6B

CH-PB-5R CH-PB-6B

head: ceramic abrasive stone (sphere: 3 to 6, column: 3 to 5) shaft: 1.5 x 40 mm shaft: 3 x 30 mm

Alumina Fiber Rod Type Target Bore Diameter in Primary Processing

Brush Diameter a

Shaft Diameter b

5 to 8mm

3mm

4mm

8 to 10mm

5mm

6mm

10 to 20mm

7mm

8mm

Shank Diameter c

Full Length

Product Code

3mm 4mm 6mm 6mm 6mm 8mm

120mm 170mm 120mm 170mm 120mm 170mm

CH-A12-3M CH-A12-3L CH-A12-5M CH-A12-5L CH-A12-7M CH-A12-7L

DEBURRING TOOL

Head Size

New New New

Chucking position marking

Precaution In Use [Pre-operation inspection] When mounting on a rotary tool, insert the shank and all the way to the bottom of the chuck, and secure it tightly. Conduct a test run for one minute or more before starting operation, and three minutes or more after changing the tool, to confirm the absence of any abnormality such as tool vibration or looseness. Even if nothing abnormal occurs during the test run, stop the tool immediately if you find anything unusual such as viration; dangerrous head or shaft breakage, deformation or even tool breakdown may occur.

[Maximum RPM] Use below the maximum 10,000 rpm for 6, 12,000 rpm for 5, 13,000 for 4, and 15,000 for 3 mm diameters. Usage above the maximum rpm may result in breakage of the head and shaft.

[Cutting load] Use a cutting load of 5N or less i.e. 500 gf, bending displacement of 2 mm or less. Usage with an excessive cutting load may cause a broken or a dangerously damaged shaft.

[Size of Target Burr] This tool is designed for removal of fine burrs where the base thickness is 0.2 mm or less after machine processing.

[Truing / Dressing] If the head (ceramic stone) deforms through usage, true the shape by lightly pressing the periphery of the stone onto an electrodeposited diamond stone under tool rotation. Do dressing same way.

[Head Size Selection] Select a head size that is slightly larger than the bore diameter in secondary processing. If a smaller head is used, it may get into secondary processing hole and may result in breakage of head and shaft.

Select the tool size corresponding to the diameter of the targeted hole. The wrong size tool can cause dangerous breakage of the brush fiber rods and shaft along with deformation and/or damage. Insert the tool tip into the cylinder before switching “ON”, or the brush fiber rods may be damaged or scatter in danger.

[Pre-operation Inspection] When the tool is machin-mounted, insert shank into the chuck up to chucking position marking on the tool (30 mm from tool end) and fix it tightly. If you find anything unusual such as vibration during tool operations use, stop immediately: or hazardous breakage, deformation, or damage to the brush fiber rods and/or shaft may result.

[Maximum RPM] Operate at less than the maximum rpm of 12,000. Usage above the maximuam rpm may result in dangerous breakage of the tool.

[Size of Target Burr] This tool is designed for removal offine burrs where the base thickness is 0.1 mm or less after machine processing.

Operator Safety Measures (For Both Ceramic Type and Aluminum Fiber Rod Type) [For Protective Equipment] Always wear protective googles, gloves and masks when operating the tool. Wear long sleeve, tight cuffs, and clothing to minimize skin exposure.

[Beware of Grinding Powder] Grinding powder and burrs may scatter within the area around the work as the tool rotation : use a dust collecting device to collect the dust.

[Caution to your surroundings] The area around your work is hazardous in case flying pieces of fiber rods from the tool and grinding powder may scatter, enclose your working area to prevent other people from entering, or have the people surrounding your work area wear protective equipment as well.

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DEBURRING TOOL

ISO 9001 Certified

Can be used with high speed rotating tools (Air type). No cracking, no chipping! No clogging! Ideal for improving surface finishes!

Feature Cutting edges are continually exposed over the entire surface thanks to self sharpening alumina fiber ceramic rod. Works great for any material up to 57HRC such as Aluminum and Stainless steel. Efficient removal of burrs with base thickness up to 0.2mm.

Please be careful with similar products.

Shape the tip for specific applications

Applications Deburring of stainless steel groove

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Breaking edge of steel workpiece

Chamfering of aluminum workpiece

AX-PM-5RF Operation speed, up to 30,000 min-1 DEBURRING TOOL

Flexible shaft allows soft contact with the workpiece Suitable for processing narrow area, thanks to the thin shaft Cutting edges are exposed to entire surface.

AX-PM-3R Operation speed, up to 60,000 min-1 Head is made entirely of Ceramic Fiber Stone with no inner shaft; eliminates wasted material. Cutting edges are exposed to entire surface.

AX-PM-6T Operation speed, up to 60,000 min-1 No core metal is used and the tool head: made of Ceramic Fiber Stone can be used up all. Cutting edges are exposed to entire surface.

Product code and specification AX-PM-5RF AX-PM-3R AX-PM-6T * All tool can be used with low speed rotating tools (electronic type).

Precaution in use

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