Rex-Cut Blog

    How To Find The Right Tool For Deburring Metal

    Most metal cutting operations including punching, shearing, and die cutting leave behind unrefined edges that often require finishing steps. Metal workers tasked with deburring aim to remove this sharp edge to spec, leaving a smooth, safe edge in a timely manner. What is the best way to complete this operation?

    We have an answer. The fastest way to debur sheet metal is to dull the top and bottom edges in one pass using an abrasive mounted point customized for the operation.  


    Deburring 101 

    Deburring sheet metal is an essential step in improving product aesthetic and shop safety. One way to reduce cuts and injuries while handling sheet metal is to break sharp edges before forming or welding and deburring after cutting applications. Final work pieces often need some deburring done both for the final look and safety. As an example, kitchen equipment can’t be installed with sharp edges exposed.

    Controlled Material Removal 


    Not all deburring tools are equal. Removing sharp edges efficiently requires a long-lasting, easy to control tool in hand. A Cotton Fiber Mounted Point is a leader in accurate deburring and improves edge quality with minimal effort on ferrous and non-ferrous metal. 

    Traditionally, deburring is done with a file which can leave inconsistent results and often requires multiple passes. Cotton Fiber Abrasives offer more control as a hand held tool and will save your staff time deburring.

    Other benefits of cotton fiber include: 

    • Even material removal
    • Chatter free operation
    • Long life
    • Debur and finish in a single operation
    • Creates rounded edge opposed to chamfered
    • Non-loading on soft metals

    Fast and controlled burr removal with cotton fiber abrasives results in shorter lead times and fewer imperfections.

    Standard Operations For Deburring

    With deburring sheet metal as a step in production, indicating specs to staff for how much metal to remove and how to do it is imperative for repeatable results.

    Set expectations for deburring with instructions like

    • “deburring not required” or
    • “remove all visible burs” or
    • “remove all burs visible at 4x magnification” 

    Without guidance, there is often a possibility of removing too much or too little material leaving parts that are off-spec. In order for your team to meet the expectations you’ve laid out, you’ll need to ensure your staff has the tools and training to perform quality work. 

    We recommend the W222 Cotton Fiber Point or W222 Rubber Mounted Point for sheet metal edge deburring. Rex-Cut Mounted Points are available in a variety of shapes and sizes for a variety of applications. 

    With the right tools, the deburring process is simple:

    • Step 1. – Secure the sheet metal to prevent slipping. 
    • Step 2. – Use a grinder with the mounted point and simply run the point over the edge of the sheet metal. 
    • Step 3. – Repeat. Run the point over the other sides to break those sharp edges. As the groove in the point wears, just move down the point to create a new groove, and so on.

    Best Bonds For The Operation

    Deburring is a delicate process. Using too hard of an abrasive substrate and applying aggressive pressure will remove material that distorts part geometry. Deburring lightly with a wheel that is too soft risks never removing the burr or needing multiple passes. Match the size, shape, composition, and hardness of the abrasive to the task at hand and see the quantifiable results in the work.

    Cotton fiber and rubber wheels are both good choices for deburring. Each has its own unique set of benefits

    Cotton Fiber Abrasive Point

    • Fast cutting
    • Long life

    Rubber Abrasive Point

    • Smooth operation
    • Less chatter

    The hardness of the abrasive wheel is a bit of a Goldilocks situation, it needs to be not too hard, and not too soft with the right type of bond to remove metal with control. We offer three main bonds in cotton fiber to suit a variety of operations. 

    The softest is GFX that has a soft yet strong quality making it the choice for both blending and light deburring. JTX is the medium bond for light to medium deburring with a longer life. The hardest is MTX for light and medium stock removal.  

    Our rubber points are made from a synthetic that is softer than natural rubber and are best for light grinding and blending soft non-ferrous metals and stainless steel alike.

    Watch our Video to learn this technique for deburring sheet metal.


    Filed under: Stainless Steel, Aluminum, Fabrication