Burr
A burr is an unwanted material protrusion that remains along the edge of a component after a thermal or mechanical manufacturing process.
Burrs can affect edge quality, downstream manufacturing operations and the further processing of sheet metal components.
How Does a Burr Form?
Burrs form when material is displaced, pushed outward or not completely separated during a cutting or machining operation. The size and shape of a burr depend on the manufacturing process, material properties and selected process parameters.
Common Causes of Burr Formation
- Thermal cutting processes
- Mechanical machining operations
- Tool wear
- Incorrect process parameters
- Material deformation at the cut edge
How Edge Radii Affect Downstream Processes
Remaining burrs can interfere with stable manufacturing processes and negatively affect component functionality. Coating, assembly and welding operations are particularly sensitive to uncontrolled material protrusions along component edges.
Typical Effects
- Increased risk of injury during handling
- Assembly issues
- Inconsistent coating results
- Unstable downstream processes
- Increased post-processing requirements
Deburring as a Process Step
During the deburring process, material protrusions are removed in a controlled manner to create reproducible edge conditions and stable foundations for downstream manufacturing operations.
Depending on the initial edge condition and the required edge quality, additional process steps such as edge rounding or surface finishing may follow.
Primary Burr vs. Secondary Burr
Not all burrs are created in the same way. In industrial edge processing, a distinction is made between primary burrs and secondary burrs.
Technical Differences
| Primary Burr | Secondary Burr | |
|---|---|---|
| Formation | Created directly during cutting or separation | Created through material displacement during downstream processing |
| Characteristic | Typically a sharp material protrusion | Typically a surface-level material buildup |
FAQ
Why should burrs be removed?
Remaining burrs can reduce edge quality, interfere with downstream manufacturing processes and negatively affect workplace safety.
Which manufacturing processes create burrs?
Burrs can occur during thermal and mechanical manufacturing processes, including laser cutting, punching, milling and drilling.