Introducing a new solution for single-step deburring and cleaning

Turbex partners Karl Roll have released a new highly-flexible high pressure water jet system that offers economical deburring and cleaning, all in one step. With FlexJet HD:

  • Burrs and chips can be removed just as effectively as welding beads.
  • Layers of paint and scale can be removed. 
  • Individually adapted nozzle systems guarantee a high degree of workpiece flexibility.
  • There’s high precision for reproducible results.

Why was FlexJet HD developed? 

In order to achieve the required cleanliness specifications in a stable manner, cleaning the workpieces alone is usually no longer sufficient. This is because burrs and chips that aren’t removed during cleaning can become detached in subsequent processes and recontaminate the component. 

The FlexJet HD is designed for machined components such as those for hydraulic and pneumatic systems, housing components, nozzles, components for gears, motors, steering and brakes, as well as workpieces for medical technology applications. Reliable deburring of the components is a must in order to meet particulate cleanliness requirements in a stable and economical manner.

How does the FlexJet HD work?

 Deburring machined components is a challenge due to areas that are difficult to access, such as internal and intersecting holes, deep and small holes, undercuts and blind holes. FlexJet HD’s high-pressure water jet provides a water pressure of around 500-bar in one work step to reach these areas. How it works is simple:

Step one: easy programming through modern control technology

State-of-the-art control technology is used to position the CNC axes, which are also used in machine tools. The process sequence can be programmed offline using G-code and a teach-in solution via a 15-inch control panel. There is also the option of programming with a handheld terminal via teach-in. These solutions enable simple and fast programming of the contours to be followed as well as very exact positioning in the areas to be deburred without special programming knowledge.

Step two: highly targeted removal of of chips and burrs

The water jet generated in the high-pressure unit is passed through a four-way nozzle system with automatic nozzle switch. For a precise and reproducible result, the workpiece can be rotated during the process as required and moved along the X-axis. At the same time, the nozzles can be moved along the Y and Z axes. This highly targeted processing not only reliably removes adhering chips from areas that are difficult to access, such as transverse and deep hole bores, but also detaches and removes clamping chips, welding beads and layers of scale. 

The FlexJet HD system ensures optimal results even with geometries and contamination where classic processes reach their limits. The water jet can be directed flat for deburring and cleaning larger surfaces. The high kinetic energy also removes stubborn contamination such as sweat residues and silicates.

Step three: effective disposal of burrs and chips

The burrs and chips removed during the deburring and cleaning process are reliably removed by an effective filter system consisting of a pre-filter and a fine filter. The process water can therefore be circulated without any problem. In addition, a safety filter is integrated in front of the high pressure pump.

What can the FlexJet HD be used for?

With pneumatic connections for automatic workpiece clamping devices, the rotary table integrated in the treatment chamber is designed for components with a diameter of up to 450 mm and a maximum height of 550 mm. The maximum workpiece weight including the clamping device is 100 kg. These dimensions make it possible to handle, for example, an engine block for a four-cylinder engine or several small parts.

Recap: why use Karl Roll’s new FlexJet HD high pressure water jet system?

The FlexJet HD meets the increased demands on particulate cleanliness efficiently and stably across a range of applications. The high-pressure water jet deburring system enables efficient deburring and cleaning in one work step. In addition to burrs and jamming chips, welding beads as well as layers of paint and scale can also be effectively removed. The low use of media and energy efficiency also contribute to the high profitability of the new system for high-pressure deburring and cleaning. 

To find out more about the FlexJet HD water jet, get in touch with Turbex today.