Process Specification

Finishing of Metal Components 80–T–30–6918

(Deburring, Cleaning) Issue: 07/98
Page 1 / 6

Contents All directives are originally compiled, checked and

approved in the German language.
In case of discrepancies which could result from
1 Scope and Application possible translation errors or wrong interpretation of
the English text, the German version of these directi-
2 Related Documents ves shall always be binding.
3 Prerequisites
4 Materials and Equipment
5 Process
6 Quality Assurance
7 Safety and Health
8 Process Flow Chart

Data Sheet 1: Not applicable

Earlier issue: 09/86

Copying of this document, and giving it to others and the use or communication of the contents thereof, are forbidden without express authority. Offend-
ers are liable to the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design.
 Page 2 80–T–30–6918 (07/98)

1 SCOPE AND APPLICATION

This process specification stipulates the requirements for finishing procedures to be accomplished
on metal components prior to the application of surface protection.
The scope of the finishing procedures per this process specification is not specified in the drawing,
as these procedures depend on the preceding work, i.e. cutting, machining etc.
Any finishing beyond the stipulations of this process specification, e.g. reworking of rounded edges
on components in corrosion–critical areas or in the case of specific static or dynamic stress condi-
tions, must be specifically referred to in the drawing.
Finishing per this process specification comprises
a) processing of component edges
b) finishing of component surfaces.
The processing of fastener hole edges is described in 80–T–30–9910.
For the removal of scratches refer also to 80–T–39–0230.

2 RELATED DOCUMENTS
80–T–30–6900 Grinding of titanium
80–T–30–6912 Grinding of high–strength steels
80–T–30–6913 Precision grinding of hard chromium layers on steel
80–T–30–6919 Vibratory grinding
80–T–30–9910 Drilling, reaming, broaching and countersinking of rivet and screw holes
80–T–33–3510 Chemical milling of aluminum and aluminum alloys
80–T–35–0204 Abrasive blasting – vapour lapping –
80–T–35–0205 Shot peening
80–T–35–9120 Coating with paints, general
80–T–39–0230 Treatment of scratches on sheet–metal parts made of aluminum–alloy
DIN 6784 Workpiece edges, Terms, Drawing indications
DAN 11304 General Tolerances

3 PREREQUISITES
3.1 Manufacturing documents
Any specific dimensional requirements for edge radii or chamfers must be shown in the drawing.
(Dimensioning per DIN 6784).

3.2 Personnel
Before starting any finishing work, personnel must be familiar with the requirements of this process
specification.
 Page 3 80–T–30–6918 (07/98)

4 MATERIALS AND EQUIPMENT

4.1 Equipment and tools
The equipment used for finishing procedures shall be adapted to comply with the maximum per-
mitted grinding speed specified in section 5.
The abrasive used with the grinding tools employed in these procedures can be either corundum
or silicon carbide. Coarse–grained abrasive, grain 80 or coarser, may be used for rough preliminary
cleaning. The finishing steps require a grain size finer than 80.
The brushes may be stainless steel or plastic with abrasive application.
Diamond files shall be used for deburring hard chromium plated components.
The equipment required for finishing operations on titanium components shall not consist of solid
grinding wheels, but must be covered with abrasive material (abrasive sheet or paper).
The grinding surface shall be mounted in a flexible support.

4.2 Components
The component surfaces/edges, and the surfaces and edges of the grinding tool, shall be free from
foreign materials that can be impressed into the surface during the grinding process. Fine layers
of oil and grease need not be removed.

5 PROCESS
The following finishing procedures may be used:
a) Filing, scraping, grinding by hand
b) Deburring by vibratory grinding per 80–T–30–6919
c) Brushing and grinding by machine–driven tools
d) Blasting (wet – dry) per 80–T–35–0204
Finishing by hand may be done by using, e.g. files, scrapers, deburring knives, abrasive sheets and
Scotchbrite mats.
Note: During the finishing process avoid local heating that may lead to tarnishing, as this might
change the mechanical properties (especially critical in the case of titanium and high–
strength steel).
The maximum permitted grinding speed is 20 m
s–1.
The grain of the abrasive used for finishing must be finer than 80. Any marks in the surface as
a result of preliminary rough cleaning activities, must be removed. The maximum roughness height
(Rmax) of the finished surface must correspond to that of a surface worked with grain size 80. If
finishing is followed by crack testing, the grain size shall be from 80 to 120 inclusive. Care must
be taken that abraded dust does not accumulate on the grinding surface. The grinding tool must
therefore be replaced at an early stage.
For particulars on the grinding of high–strength steel and titanium, refer to 80–T–30–6912 and
80–T–30–6900.
 Page 4 80–T–30–6918 (07/98)

5.1 Finishing of component edges

Components Process Remarks

Machined components – Finishing by hand All radii/chamfers at exposed
(see 5) edges must be  0,15 mm
– Vibratory grinding per
80–T–30–6919
Machined sheet metal – Finishing by hand Free from burrs per DIN 6784
components (see 5)
– Vibratory grinding per
80–T–30–6919
– Brush deburring
Chemically milled of the last For milling depths  2,5 mm Free from burrs per DIN 6784
chemical milling stage (milled – fan grinding Direction of grinding must be
edges), plated/not plated (grain size 150) transverse to milled edge
For milling depths
2,5 mm If it is not possible to work in
– hand milling cutter specified direction, proceed
per 5.3
Skin panels Free from burrs per DIN 6784
a) curved Finishing by hand Deburring by hand applies to
(see section 5) the following component areas:
b) flat – Finishing by hand and de- all edges of longitudinal and
burring with brush circumferential joints; and
cutouts
Hard chromium plated Finishing of edges with dia- Free from burrs per DIN 6784
components mond file See also 80–T–30–6913

Edge finishing shall produce an edge of the category ”free from burrs” as defined in DIN 6784.
Note: Only the two exterior edges have to be deburred, when installed sheet metal packages are
being milled to finish dimension during assembly.

5.2 Finishing of component surfaces

Components Process Remarks

Removal of tool marks – Finishing with milling cutter See instruction in manufactu-
(milling cutter offset or line or grinding by hand or with ring document
offset) hand grinding tool
– Blasting per 80–T–35–0204
Surface blemishes – Finishing by grinding See DAN 11304,
(faults in semi–finished mate- – Grinding by hand or with 80–T–39–0230
rial, corrosion, roughness) hand grinding tool
– Blasting per 80–T–35–0204
Work defects – Finishing by grinding See 80–T–39–0230
(scratches, irregularities and/or – Grinding by hand or with
holes after chemical milling, hand grinding tool
running untrue of milling cut-
ter)
 Page 5 80–T–30–6918 (07/98)

5.3 Repair of inferior finishing work at chemically milled edges

If finishing work produces grooves which are transverse to the direction of load and parallel to
the chemically milled edge, the following repair is permitted:
Blasting in the area of the chemically milled edge per 80–T–35–0205 (intensity 0,04 N to 0,15 N,
depending on the sheet thickness).
Make sure that, after blasting, there are no visible grooves running parallel to the chemically milled
edge.

6 QUALITY ASSURANCE
Unless specified otherwise in process– or component–specific design, manufacturing or QA docu-
ments, the competent segment has to ensure that the following measures are taken:
Inspection schedule

Object Scope Inspection

Machined components at discretion of works quality as- Visual inspection per 6.1 and
surance 6.2
Components deburred by hand all components Inspection per 6.1, 6.2 and 6.3
Components deburred with one component per production
machine batch
Skin panels all components Inspection per 6.1, 6.2 and 6.3
Components, chemically milled all components Inspection per 6.1, 6.2 and 6.3
per 80–T–33–3510 and debur-
red by hand
Components, chemically milled one component per production
per 80–T–33–3510 and debur- batch;
red by machine chemically milled edges on all
components
Installation and/or procedure To be defined per works–speci- Inspection per 6.2, 6.3
for machine deburring fic instruction

6.1 Visual inspection

Visual inspection of components for
a) Discoloration on titanium components (not permitted)
b) Discoloration on steel components (not permitted)
c) Absence of burrs (including secondary burrs); definition see DIN 6784
d) Surface damage, as defined in 80–T–39–0230
e) Surface defects, e.g. from rolling, corrosion etc.
f) Processing marks after finishing on chemically milled edges (not permitted when parallel with
chemically milled edge).
 Page 6 80–T–30–6918 (07/98)

6.2 Inspection of edge geometry

Where radii are defined in drawings, they must be checked per design document and/or inspection
schedule.
The edge radius/chamfer of outer edges of machined components must not be less than 0,15 mm.
For all other cases absence of burrs is a basic requirement.

6.3 Inspection of surface finish

The surface finish (roughness or waviness) must be as specified in the design document.
The quality is demonstrated with the aid of reference standards or with suitable measuring equip-
ment on the surfaces/edges listed below:
– chemically milled areas (area of finishing)
– milled areas
– processed edges

6.4 Inspection of component edges after application of surface protection

For thickness of paint layer on edges, see 80–T–35–9120.

6.5 Inspection of installations and deburring procedures

Any inspection of the deburring installations, using samples or series–production components, must
be accomplished in the presence of quality assurance staff.
In the case of defined machine setting parameters, the edge formation is checked by comparison
with a sample.

7 SAFETY AND HEALTH

Apply the local safety regulations.
It is the responsibility of the user of this standard to apply appropriate safety and health practices
and determine the applicability of regulatory limitations prior to use.

8 PROCESS FLOW CHART

Not applicable.