Stationary deburring machine
Identical workpieces, fixed clamping position, fixed nozzle systems sufficient — more cost-effective than robotics where the task allows it.
„We cannot get the burr off.“
Machinery manufacturing
Cross bores and cross-drilled holes, burr root, blind holes, residual contamination in the hydraulic channel, repeatability, verification requirement — that is the task. The system is its result.
1 · The challenge
The problem almost always sits inside the component
A valve block or hydraulic manifold is at its core a block of material with a channel system inside. The channels are drilled, they intersect several times, and a burr forms at every bore intersection. No mechanical tool reaches any of these places.
And the burr is not the end of the story. It comes off later and travels with the medium through the component, into hydraulic and oil channels, to valves, into pumps. A detached burr in the channel is not a form deviation but residual contamination — and thus the same question every parts cleaning system has to answer.
The same geometry also makes cleaning hard. Blind holes and branched channels are exactly the places a spray jet does not reach: it hits what it sees. What it does not see stays untreated — and becomes visible in the residual contamination verification.
What really counts about the burr
The burr root
How firmly the burr is attached to the component. It determines how much energy is needed to detach it.The accessibility
Whether a tool or a jet reaches the place at all.
It is not the size of the burr that decides, but these two. A burr you can get at is a manufacturing task. A burr at the intersection of cross bores is a design engineering task.
What the problem sounds like at the customer
„We cannot get the burr off.“ · „The parts do not come out clean.“ · „There is too much oil on them.“ · „The residual contamination values are not within limits.“ · „The cleanliness requirement is not being met.“
The second starting point is an economic one: deburring is done by hand. That works as long as the production volume is small and nobody demands verification. As soon as one of the two tips, quality depends on the form of the day and the cycle on the number of hands.
2 · Which components are involved
Not a list of industries, but a shared feature
What matters is not which machine the part is installed in, but what it looks like inside. What is shared is the deburring task, not the design.
Valve blocksHydraulic manifoldsPump housings
Cross bores and cross-drilled holes
Burrs at the bore intersections — not reachable mechanically.Blind holes
Spray shadow; the medium has to be brought in differently.Channels carrying flow
The function of the component depends on the cleanliness of the channel.Tight tolerances at sealing faces
The burr may be removed, the edge must not be changed.
The last point is also a limit. The water jet removes the burr — it does not shape the edge. Where a defined chamfer or a radius is required, a different process is right. We say that before the quotation, not at acceptance.
Materials
Aluminum and aluminum die casting are the focus — not as a property of the process, but because modern housings and blocks are predominantly made that way. We process steel, stainless steel, brass, copper, zinc die casting and plastics just as well. There is no limit at the material: what is decisive are part geometry, burr root, accessibility and process target.
Hydraulics
Hydraulic components are listed on this page as part of machinery manufacturing — manifolds, housings and valves follow the same logic of geometry and cleanliness.
3 · Which requirements follow from that
What stays in the channel stays in the system
The required component cleanliness depends on the downstream manufacturing process. In machinery manufacturing a second reference comes in: the function of the finished component. A hydraulic manifold is not only installed, it carries flow.
Verification 1 · Residual burr
Is the burr gone?Verification 2 · Residual contamination
Is the part clean?
Both come from one source with us. Available for testing are visual inspection, camera-based inspection, residual burr inspection, residual contamination analysis and process monitoring — which of them are used in the individual case we define together with you.
The residual contamination analysis is carried out by an independent, accredited test laboratory — not by us. For technical cleanliness requirements, measurement follows your specifications or the relevant standards such as VDA 19 / ISO 16232, where these are required.
4 · Which solutions answer this
Deburring is the core topic here
The high-pressure water jet reaches the bores and internal channels that mechanical tools cannot. With these components that is not one advantage among several, but the reason why the process comes into question at all.
4.1 · Three machine concepts, three arguments
Single-robot cell
High flexibility, different components, complex geometries, small to medium series.
They do not differ in quality, but in the argument. With us the robot solution is the standard; we design without a robot when a fixed clamping position is enough and the simpler solution is more cost-effective.
Where a component has different burr locations, a cell can carry several nozzle tools via a tool changer and change them during the process — instead of working with one compromise for all locations. We design the pressure to the task, not from a catalog.
4.2 · Cleaning — when the medium has to get into the blind hole
Where spraying fails at the spray shadow, immersion and flooding lead to the result: the component is fully immersed in the medium, or the medium is guided over and around the workpiece at high volume.
Immersion cleaning system
When the workpiece has to be fully immersed so that the medium reliably reaches all areas.
Chamber cleaning system
Changing range of parts, several process steps in one closed chamber. For bulk parts usually as flood washing inside the chamber.
Spray-immersion cleaning system
When a component needs both: accessible outer surfaces and internal cavities — in one chamber, with the batch rotating and swiveling as it does.
Continuous and rotary indexing cleaning systems
Where the cycle is measured in seconds and the system stands in a line.
We add ultrasonic cleaning where immersion and flooding processes are used.
4.3 · Automating
Loading and unloading, linking, buffering: we deliver the cells and systems with automated loading and unloading — with robot, handling or material flow and conveying technology from our own design engineering. Whether it pays off, we calculate beforehand.
5 · What we do ourselves in engineering
Anyone who builds machines asks what is created in-house
That is why this section is on this page and not in the fine print. We develop complete automation solutions as part of special-purpose machine building — mechanical design engineering, project engineering, PLC and robot programming, control cabinet manufacturing, gripper technology, conveying technology, material flow, assembly, commissioning and service.
We use standard components and purchased parts where they make technical sense. The integration and the engineering of the overall solution take place with us.
PLC and robot programming are two disciplines
Not one. We do both in-house, project by project.We design both nozzles and fixtures
Besides standard nozzles we develop and manufacture nozzle geometries of our own where the application requires it — and the clamping fixture to go with them. So both sides of the process are created with us: what holds the part and what removes the burr.
During deburring a jet of several hundred bar works against the component. The clamping fixture has to absorb that force and at the same time leave every deburring location freely accessible. That is why it is an engineered part of the process, not an accessory.
6 · When our system goes into your line
Machinery manufacturing customers link systems
A system rarely stands alone — usually it is connected to existing machines, often to machines from other manufacturers.
If an existing production line is extended or several systems are linked with one another, an assessment of the overall installation is carried out within the scope of the project.
We assume responsibility for our own scopes of supply and services. Responsibility for machines from other manufacturers remains with the respective manufacturer or is governed by the contractually agreed project scope.
That is not fine print, but the point at which it shows whether someone has built lines before. We say beforehand what we stand for and what we do not.
7 · Where we advise against it
Water jet deburring is not always the optimal solution
Defined chamfers or radii are required
The process removes burrs, it does not replace machining.Very firmly adhering or massive burrs
They have to be eliminated differently, in the design or in the manufacturing process.The deburring location is not reachable with any nozzle concept
Whether it is reachable is decided by the geometry, not by the size of the burr.It is not economically sensible
For instance with very small production volumes or when a simpler deburring process is sufficient.A different process meets the requirements better
Technically or economically.
Plus two limits from cleaning: unrealistically low residual contamination requirements we decline before the quotation, not at acceptance. And baked-on contamination is the most difficult case — where it occurs, we clarify feasibility early. And one from automation: with low production volumes, frequently changing products or high changeover effort we recommend no automation — even when it would be technically possible.
8 · Where we stand in machinery manufacturing
Machine tool manufacturers are our customers
Anyone who builds for machine builders builds for people who can judge a machine — and who ask before buying what is actually created in-house.
Already realized
Industrial Parts CleaningHigh-Precision Water Jet DeburringAutomation & Robotics
Our customers include manufacturers of machine tools, pumps and valves, rolling bearings and drives as well as companies in measurement and production technology. The industry is not a coincidence of sales but the consequence of the components: wherever internally branched blocks and housings are produced, burrs form at bore intersections and residual contamination in channels.
These blocks and housings originate predominantly as die-cast parts — the same components, one manufacturing step earlier.
9 · Scope of supply
Vertical integration, acceptance and digital system lifecycle
Questions and answers
Frequently asked questions from machinery manufacturing
Which parts cleaning system is suitable for complex components with blind holes, cross-drilled holes and high requirements for technical cleanliness?
It is not the size of the component that decides, nor the amount of contamination, but the geometry and the question of whether the medium reaches the critical spot. The spray jet hits what it sees — with blind holes, cross bores and cross-drilled holes and branched internal channels, the spray shadow remains. Where spraying fails at that, immersion and flooding lead to the result: the component is fully immersed, or the medium is guided over and around the workpiece at high volume. If a part needs both — accessible outer surfaces and internal cavities — a spray-immersion cleaning system comes into question. Where the cycle is measured in seconds and the system stands in a line, it is continuous or rotary indexing cleaning systems. Which design it becomes in the end arises from the interplay of part geometry, material, type of contamination, required residual contamination quality, cycle time, production volume and material flow. There is no fixed rule „this component, that machine“ — the system is designed, not selected.
Applications
Tasks from this industry
2 worked-out tasks are assigned to machinery manufacturing. What tips the balance in each of them is on its own page.
Every case lists the design factors, the possible system concepts and the processes in detail — here is only what it is about.
Hydraulic manifold
A hydraulic manifold is not only installed, it carries flow — what stays in the channel stays in the system.
Valve block
The burr root sits at the bore intersection of two bores — no tool gets there, not because it would be too big, but because no path leads to it.
The assignment classifies — it claims no project. And it decides nothing about the system: which concept a task needs arises from the interplay of the design factors, not from the industry.
Direct contact
AddressITR GmbH powered by Zippel
Hauptstraße 31
93186 Pettendorf
Pettendorf bei Regensburg
Hauptstraße 31
93186 Pettendorf
Pettendorf bei Regensburg
Phone+49 (0) 9409-777 3598
Fax +49 (0) 9409-777 3607
Fax +49 (0) 9409-777 3607