The Importance of Leveling and Deburring in Sheet Metal Processing
Whether from the coil or from the blank - in order for the final quality to be right, the sheets must be leveled and deburred. There is a whole range of machining processes that run more reliably and precisely with perfect sheets. In this article, we will reveal what these are.
When working from coil, the rule is: as little downtime as possible on the coil! For maximum productivity of punching machines and presses, coil lines are available in short or long design. A leveling unit is always included, which at least eliminates coil curvature. With a high-quality leveling unit, constant drawing ratios can also be achieved. This makes forming easier, tool consumption and variance are lower - and users save storage costs.
Productivity counts when working from coil
In fineblanking, good coil guidance ensures high stroke rates. With their leveling unit, the coil lines enable fast and efficient production. With precise feed technology, even tight component tolerances can be maintained. And they do so permanently and consistently reproducibly. This means that even complex components are no problem.
In the profiling process, the coil preparation lines enter into a symbiotic relationship with the profiling lines. Pre-punching, strip end welding and strip accumulator systems can be components of a coil preparation line. Together with the leveling unit, they ensure perfect results and high productivity.
1 Stamping & blanking: Shorter line downtimes: our CompactFeed® compact-design press feeding line and the EcoLine® long-design feeder ensure higher productivity on the production line. A consistent feed simplifies the forming process, reduces the consumption and variance of the tools while also saving you storage costs.
2 Fineblanking: More cycles thanks to exact coil feeding: the EcoLine® long-design feeder and the CompactFeed® compact-design press feeding line form the foundation for your rapid and efficient production. Our precision feeding technology lets you maintain narrow component tolerances – permanently and with consistent reproducibility. As a result, even complex components are no problem at all.
3 Roll forming: ARKU’s coil preparation lines work in perfect combination with the roll forming lines. Pre-punching, coil welding and coil storage solutions can be an integral part of a coil preparation system.
4 Shearing: The HiCap® high-performance leveler integrated into ARKU’s shearing lines ensures flat panels with low internal stresses along with even surfaces. Using the rotary shears from ARKU, you achieve low tolerances for the final product. This enables the subsequent processes to run constantly.
The coils often have to be cut into manageable pieces. When cutting to size, a high-performance leveler in ARKU's slitting and cut-to-length lines ensures flat, low-stress blanks and uniform surfaces. With the rotating shears, users achieve tight tolerances in the end product. And subsequent processes can run consistently in this way.
Perfectly prepared parts when working from the board
When working from the sheet, laser cutting is now one of the most important processes. Levelers ensure flat and stress-free parts after laser cutting. This creates optimum conditions for subsequent processes such as bending, welding, painting or electroplating.
Flame cutting or plasma cutting is usually best suited for cutting thick sheets. However, these cutting processes easily produce slag and burrs. The high energy input during cutting can also lead to stresses and unevenness in the sheet metal parts. This makes subsequent work more difficult. Part levelers and deburring machines provide a remedy and ensure greater process reliability and cost-effectiveness. Even flame-cut parts become uniform through deburring. At the same time, working conditions for employees are improved: deburred parts allow easier handling and reduce the risk of injury.
1 Laser cutting: ARKU levelers ensure flat parts with low internal stresses after laser cutting, creating the perfect preparation for subsequent processes. For optimum coating and galvanizing results.
2 Plasma and Flame cutting: Plasma and flame cutting often results in slag and burrs. Stresses and deformed components cause problems during subsequent work. ARKU parts levelers, deburring and rounding machines provide the solution and give your company greater process reliability and efficiency. Higher quality in less time. Deburring provides oxyfuel-cut parts with a uniform shape. At the same time, you also improve your employees’ working conditions through safe parts handling and a reduced risk of injury.
3 Bending: Brackets and components require precise dimensions for bending, especially on automated production lines. ARKU parts levelers provide optimum preparation. The parts are flat and have minimal internal stresses. ARKU deburring and rounding machines create burr-free and rounded panels that are perfectly prepared for the subsequent steps. Your employees benefit from the safer and more efficient work with ARKU systems.
4 Punching: Uniform punched parts thanks to machine leveling, deburring and edge-rounding – with ARKU parts levelers and deburring machines. For flat sheets with low internal stresses. Compliance with tolerances and improved haptics mean that the parts are optimally prepared for subsequent processes such as bending, edging and welding. The preparation also improves painting and galvanizing processes. Automated processes with consistent quality make your production safer and more productive.
5 Welding: Leveling and deburring your sheet metal parts before welding saves you valuable time. The welding systems process the parts faster and allow for easier mounting in the welding fixtures. The welding itself is faster and finished assemblies no longer require reworking. Thanks to ARKU parts levelers and deburring machines robot welding is more reliable thanks to the perfect and consistent weld gaps.
For bending, angles and components must be precisely machined - especially in automated production. Part levelers ensure optimum preparatory work, the parts are stress-relieved and level. Deburring machines ensure burr-free and rounded sheets that are optimally prepared for subsequent work. This enables employees to work more efficiently and safely.
During punching, machine leveling, deburring and rounding ensure uniform punched parts. The leveling process makes the sheets stress-relieved and flat. The unavoidable punching burr is removed by a deburring machine. Maintained tolerances and an improved feel prepare the parts for subsequent processes such as bending, folding and welding. Painting or electroplating is also simplified. Automated processes with consistent quality make the plants more productive and safer.
If the sheet metal parts are leveled and deburred before welding, this saves valuable time. The parts can be mounted more easily and quickly in the welding fixtures, welding is faster and finished welding assemblies no longer need to be reworked. Robot welding in particular becomes safer thanks to part levelers and deburring machines, as the welding gap is correct.
Conclusion: The leveling and deburring of sheet metal is not a luxury, but contributes significantly to productivity in sheet metal processing. Therefore, these processes should not be missing in any sheet metal processing.