ATB Brush Tool Implementation

Optimal life and cut will be obtained by finding the proper balance between brush speed (RPM), part penetration, and line speed.

The Maximum Safe Free Speed (MSFS) printed on the brush is not the ideal working speed. In most operations, a lower speed will prove more efficient. Optimal operating speed is typically 50-70% less than the MSFS. Lower speeds and lighter pressure give longer brush life, generate less heat, and require less power.

Where higher brush speeds and pressures are required, it is recommended to use a more aggressive brush tool. This may be done by increasing abrasive grit size, changing filament shape, increasing fill density, decreasing trim length, increasing the brush diameter, and/or slowing line speed.

Suggested ATB Wheel Brush Operating Parameters

• Depth of penetration should be set while the brush tool is rotating at operational speed.
• Precise edge radius can be controlled by adjusting the line speed.
• Slower line speed results in more aggressive brushing action.
• Surface speeds should always be kept below 3500 surface speed per minute wet and 2500 surface speed per minute dry.

Recommended Horsepower

Download: ATB Operating Parameters Reference Card (800kb)

Suggested ATB Disc Brush Operating Parameters

Tool Path Considerations:

For consistent results in an automated environment, careful consideration should be given when implementing ATB brush tools.
Download: ATB Operating Parameters Reference Card (800kb)

Tool Path:

The brush should start and finish its path completely off the part.

Rotational Direction:

The initial pass of the brush tool should be rotated in the direction opposite of the cutting tool that created the burr.

Part Coverage:

(Figure A)	(Figure B)
There are two different ways to efficiently finish a part. The ideal (Figure A) is to use a brush which is approximately three inches larger than the work piece. If a smaller brush is required due to application restrictions, (Figure B) the centerline of the brush tool should be aligned with the targeted edge.

Brush Tool Wear Compensation:

The following are the four most commonly used methods to compensate for brush tool wear.

Automatic Indexing is a technique involving indexing the brush tool in the Z axis after a predetermined number of parts. It is a commonly used technique in CNC machining centers.

Probing is a technique that helps maintain a constant depth of penetration. It is a feature specific to certain machines.

Amperage (Amp) Metering is a technique that consistently monitors the amp reading to maintain consistent pressure. This feature requires the addition of an amp meter to the process.

Manual Indexing is a technique where the operator manually adjusts for the wear on the brush using historical statistical data.

Coolant:

ATB filaments are designed with heat stabilizers and are able to withstand most applications dry.
However, coolant is always recommended for applications on very thin parts, requiring high penetration, and/or high speeds.
Coolant provides an ideal working environment for ATB filaments.

ATB Brush Tool Implementation: