Processing Plate: Equipment manufacturer’s new machines deburr and round distorted heavy blanks
 

January, 2025- Sheet metal often carries slight variations in thickness and can be distorted by heat input during the cutting process. These issues can be problematic for secondary operations such as deburring, rounding and descaling, which places special demands on grinding technology Workpieces that are several meters in size and weigh several tons such as components for excavators or large construction machines can be especially challenging. The thickness tolerance for a 2-in. sheet for example, is up to 1/10 in., according to DIN plus-and-minus tolerance specifications [up to a total of 2/10 in.]. A good processing machine must be able to handle these different framework conditions and other variables.

Conventional grinding machines usually work from above, posing another hurdle. To deburr the underside of the workpiece, it must be turned by hand or with the help of lifting equipment, depending on its size and weight. This is labor intensive, time-consuming and can be hazardous to workers.

To simplify and streamline these processes, advanced Weber systems were developed for the efficient machining of solid heavy plate parts. 

SIMPLIFY & STREAMLINE

Weber’s machines will guide tools over the surface one after the other  from both sides. This significantly reduces processing time and eliminates the need for workpieces to be manually turned between steps. Suspended from the units, the tools orbit the workpiece, a feature that gets rid of the typical problems associated with heavy, large, distorted sheet metal parts covered in thick slag.

Weber machines are able to cleanly remove stubborn pieces of slag with slag hammers. They deburr, round and grind more efficiently and with a higher throughput than conventional heavy plate processing systems. They easily compensate for differences in thickness and/or distortion of up to 4/10 in. both from above and below.

The patented DR planetary head units contribute to the high flexibility of Weber solutions and their superior performance results.

Weber’s technology eliminates the problems associated with heavy, large, heavily distorted sheet metal parts covered in thick slag.

Patented double-row planetary head units play a central role in the flexibility and performance of these solutions. They move toward or away from the workpiece depending on the load, which ensures efficient deburring and correct rounding of the edges.

The patented, single-row planetary head system, for example, is characterized by a large overlapping area of the individual tools, without lateral oscillation. The double-row planetary head, on the other hand, achieves particularly good rounding results and at the same time reduces abrasive wear to a minimum.

The floating mounting of tools and units means that the workpieces do not have to be laboriously aligned before machining.

The floating mounting of tools and units means that the workpieces do not have to be laboriously aligned before machining. The machine simply adjusts itself. The sheet metal parts can be processed directly and simultaneously in a single machine pass.

SUPERIOR RESULTS

The STC stud grinding beam also achieves superior machining results. It is characterized not only by a constant sanding pressure, but also by a high tolerance compensation. The sanding belt is held at, under tension a few millimeters downward. Due to the long contact with workpiece surfaces, it automatically works harder on all edges without creating secondary burrs. This results in consistently high sanding quality and a high material throughput, even with very thick and uneven workpieces. In addition, the long service life of the sanding belt keeps operating costs low.

The deburring systems work automatically in a job-controlled manner: As soon as a workpiece reaches the processing area, the control system recognizes it and automatically starts to remove protruding burrs, scale particles or other unwanted segments from the surface.

This combination of planetary heads, flexible bolts and double-rotating brushes opens a new dimension in high-precision heavy sheet and plate processing. Slag and scale are easily and completely removed, edges are perfectly deburred and rounded, surfaces are flawlessly ground in a single pass working from above and below.

Hans Weber Maschinenfabrik, hansweber.de.