Technical
The burr cut is the head or fluting pattern which describes the arrangement of the cutting teeth on a carbide burr, and each cut produces a different chip. The most popular cut is double cut as it is versatile and can be used for most applications. Softer metals such as aluminium or zinc should not use double cut because the teeth become loaded. The non-ferrous cut solves this issue with a deeper flute structure.
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Double cut is the most popular as it allows rapid stock removal on harder materials. The chisel tooth pattern minimises tool chatter and helps to eliminate loading the flutes. Excellent tool control is realised because of a reduced pulling action. |
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Non-Ferrous cut allows extremely fast stock removal of softer materials such as aluminium and zinc. The deep flute structure helps to eliminate burr loading. |
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Single cut or standard cut can be used on a diverse alloy range like double cut however it is better on relatively harder alloys which will not load the flutes. It has a smooth finish and produces sharp slither chips. |
| Measurement | Description | Diagram |
|---|---|---|
| D1 (mm) | Diameter of the burr head |  |
| L2 (mm) | Length of the burr head | |
| D2 (in) | Diameter of the burr shank | |
| L1 (mm) | Length of the burr | |
| Angle | Angle of the burr head |
Keep the burr moving
Beginners often mistakingly push the burr directly on to the metal surface which digs in and then spins out scoring a line in the metal. It is best to keep a smooth controlled action back and forth and if possible finish on an up stroke resulting in a better finish.
Maintain straight wrists
Experienced burr operators move the whole arm in a smooth motion. This makes it easier to keep the burr at the correct angle and pressure on the grinding surface. Think of the die grinder as an extension of your arm. The added benefit is that this reduces the chance of injury.
Avoid excessive pressure
Applying excessive force will blunt your burrs prematurely, the same as using a drill bit. Apply just enough pressure to allow the burr to do the work.
Use the correct cut, shape and size
Choosing the carbide burr with the correct size, shape and cut is critical for quality and productivity. The incorrect burr for the job can make completing the job difficult or impossible. Each burr shape is suitable for a different function so choose wisely. It can be beneficial to have a carbide burr set or a range of carbide burr bits in your toolbox. Aluminium and other soft metals require a non-ferrous cut burr for working at optimal speed.
Use the correct speed
The diagram below shows that the larger the diameter of the burr head, the slower RPM required of the die grinder. Extra long burrs with 6mm shanks over 150mm long and 3mm shanks over 50mm long should be used at reduced speeds.
Maintain straight wrists
Using carbide burrs with bent wrists increases the likelihood of carpal tunnel syndrome. The length of time and the forces the wrist is subjected to compound the chance of injury. Experienced users often move the whole arm in a smooth motion and do not apply too much force. Think of the die grinder as part of your arm.
Avoid holding awkward positions
Otherwise known as static muscle loading. Holding your tool for extended periods of time at an awkward height or angle will create excessive fatigue. The tool should be used with the arm and shoulder in a natural position. The heavier the tool the quicker the fatigue. Using the correct size die grinder or Dremel suited to the task will reduce this risk.
Protect your eyes
Wear your safety glasses or full mask during all burring operations.
Protect your ears
Your brain adjusts to high volume noise so you can be unaware of the damage happening to your ears. Noise can result in permanent loss of hearing. Ear plugs or ear muffs should be worn in noisy environments.
Reduce repetition
Avoid repetition by switching between left and right hands or alternating tasks and swapping roles with other workers.
Avoid tools that concentrate stress on the hand
Pressure on the soft tissue of the hand can inhibit nerves and blood flow. A cheap tool that digs into your hand is not suitable for prolonged periods of use. Choose more ergonomic tools for larger projects. Well designed tools required very little hand force.
Use less force
Experienced deburrers do not apply much force. A smoother action gives a better finish and greatly increases the life of the carbide burr. This optimal method is also less fatiguing for the user.
Accidental injury
Respect the danger of the tool. Too often avoidable injuries occur, such as die grinder that is still running being dropped onto a worker's leg or arm causing the carbide burr bit to remove the skin, or a person checking the temperature of a carbide burr with their fingers results in burns.