Abtex Corporation | A Deburring Technology Company

Application Solutions

Abtex manufactures a full range of deburring and surface treatment systems that are designed to address each customer's specific application, including our Nylon Abrasive Brushes. Abrasive filaments have been used in brush format for a variety of industrial applications including deburring, edge radiusing and surface finishing.

Abtex fiber abrasive brushing tools are available in disc, radial wheel, tube, end type and cylindrical formats. We offer a wide variety of stock brushes as well as custom designs for specific applications.

Our strength is our ability to design a brush for your specific application. A flexible manufacturing process enables us to customize the brushing tool; guaranteeing that an Abtex brush will always be the most effective and cost efficient for your application.

If you have an application issue that you would like help with, please use the Request Information form and send us your application requirements so we can customize a solution for you.



Aluminum Extrusion Deburr

Challenge: After saw cutting operation part ends need to be made burr free for handling and downstream operation.

Current process: Customer has been using abrasive nylon and wire brushes on a buffing stand but results have been inconsistent and an increase in orders requires another method be found.

BeforeAluminum Deburring Before
AfterAluminum Deburring After

Abtex Solution: Abrasive nylon brushes are an excellent tool for deburring aluminum extrusions but presenting the part properly to the brush is key in achieving good results. With an Abtex End Deburring System brush penetration is maintained so that consistent results are achieved from part to part. Customer can now easily handle the increase in production and at the same time has a manageable deburring process for this and other extruded parts they manufacture.

Time/labor saved: Where only a few irregular parts could be processed each minute they can now do as many as 20 parts per minute with consistent results.

Recommended brushes

Semi Auotmatic End Deburring System   

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Machined Part Deburr

Challenge: Customer is doing small runs of this and other machined parts and is looking for a better way to remove remaining burrs.

Current process: After removal from the machining center the operator with various hand tools works at removing the burrs while the next part is machined.

BeforeMachine Applications Deburring Before
AfterAluminum Deburring After

Abtex Solution: To achieve more consistent results the deburring operation was moved into the machining center and done with abrasive nylon brushes made by Abtex. One of our 4” 80 grit disc brushes was able to remove the burrs and at the same time provide a light edge radius to what were before sharp areas on the part. With the help of modified fixturing multiple parts can now be machined and deburred leaving the operator free and reducing repetitive motion issues.

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Sintered Powdered Metal

Challenge: Customer is a large automotive parts supplier and needed to remove burrs left by a double disc grinding operation.

Current process: This customer had an older piece of brush deburring equipment that was frequently down for repairs and with part production increasing it could not be relied upon.

BeforeSintered Metal Deburring Before
AfterSintered Metal Deburring After

Abtex Solution: Needing to improve efficiency, reliability and provide consistent burr free parts the Abtex Tri-Ten Planetary Deburring System was an ideal solution. With the brushes abrasive filaments striking the part edges from all directions and being monitored by auto compensation software burr removal and edge radius quality were both improved. By using the Abtex Planetary System this customer was able to improve part quality with a higher production rate which allowed them to win additional business. They have since added two more Abtex Planetary units to their facility.

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Fineblank Deburr

Challenge: This customer produces a variety of fineblanked parts and was looking to increase their deburring capacity along with making their deburring process more efficient and cost effective.

Current process: Being deburred on some older equipment these parts would first have the primary burrs removed by a belt sanding operation and then the remaining secondary burrs would be addressed by abrasive nylon brushes.

BeforeFineBlank Debur Before
AfterFineBlank Debur After

Abtex Solution: By going with one of our Tri-Ten Planetary Deburring Systems the customer is now able to remove both the primary and secondary burrs with a similar approach. Taking the place of the abrasive belts a burred part upon entry to our machine first passes under a planetary head equipped with our coated abrasive flap discs. Unlike belts these discs are continually exposing new abrasive as they wear which keeps the primary burr removal process much more consistent and allows the abrasive nylon brushes to perform better.

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Brush Replacement

Challenge: This customer has a piece of equipment that was not built in the US and requires a uniquely designed brush for the application. Price and delivery have become concerns and the customer wanted an alternative brush source.

BeforeBrush Replacement Before
AfterBrush Replacement After

Abtex Solution: Through initial contact with one of our Sales Representatives the customer supplied us with an understanding of the brushes requirements along with a used sample. This allowed Abtex to design a replacement that both fit their equipment and performed as needed. With improvements in brush life, cost and delivery Abtex has now become their preferred supplier.

 

Brush Replacement

Challenge: This customer supplied us with a brush not manufactured in the US and required to localize purchasing of this product. Price and delivery have become concerns and the customer wanted an alternative brush source.

Key Factor: The current brush has conductive brass filaments to make contact with the current back up plate for their equipment to be able to monitor brush contact with the part.

   Before
  After  
   wire disc brush   wire silicon abrasive disc brush
 

Abtex Solution: Through initial contact with one of our Sales Representatives the customer supplied us with an understanding of the brushes requirements along with a used sample. This allowed Abtex to design a brush replacement with conductive brass and nylon abrasive filaments that easily attaches to the customers arbor that both fit their equipment and performed as needed. With improvements in brush life, cost and delivery Abtex has now become their preferred supplier.

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Polycarbonate Deburr

Challenge: Customer is turning down a large volume of polycarbonate plastic shells on a lathe to reduce their diameter. The cutting tool leaves a "stringy" burr as shown in the "before" picture.

Current process: Customer was using deburring knife by hand to remove excess material/burrs. The process is time consuming given the complex geometry of the part and risks repetitive motion injury for the operator.

Before
Polycarbonate Before Deburring
After
Polycarbonate After Deburring

Abtex Solution: Abtex recommended contacting the rotating part in the lathe with a 6", .040"/80 grit radial wheel brush. The lathe operator holds the stationary radial wheel against the rotating polycarbonate shell to remove burrs in one direction. The lathe operator then reverses lathe direction and again holds the radial wheel against the shell. As seen in the "after" photo, burrs are completely removed.

Time/labor saved: Approximately 1 minute/part

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