The type of machining operation, size of the burr, hardness of the material and location of the burr will help to determine the method of deburring by hand. Countersinks, oversized drills, or oversized reamers may be used to deburr holes. Rotary tools, files, and abrasive stones can be used for edges of parts.
Michael Tolinski, contributing editor of Manufacturing Engineering Magazine, notes the existence of 117 deburring methods for high-volume operations. These range from burning off burrs in a sealed chamber to the use of rotary tools. The use of wet or dry machining and machining process used will be instrumental in determining the deburring method.
In some cases, the deburring can be part of the machining process through the use of rotary tools. In other cases, the geometry prevents this approach and the deburring must be done in several steps using a chisel-shaped tool, end mill or fly cutter. Some parts will be created by multiple machining methods that result in different sized burrs. Multiple deburring processes may be necessary on a single part to maintain correct the dimensions.
Dr. L. K.Gillespie notes the existence of more than 2,700 types of chamfering tools and countersinks. The designs are based upon the number of flutes for carrying away chips, coatings, material from which the tool is made and the size of burrs that can be removed. Countersinks are tools that feed into the entrance of hole like a drill. A single cutting surface or multiple cutting surfaces may be employed to remove a burr.
Some tools can eliminate large burrs. The number of flutes on the deburring tool and hardness of the materials are factors in the tool's ability to cut the burr. Other tools are designed for fine finishes. Some tools are for capable of deburring materials that have low or medium hardness. Others can deburr hardened materials. The purpose of these tools is to deburr the edges of holes.
Burrs can occur in locations that are difficult to access. Wet methods can be used for some such locations. One method is to direct streams of highly pressurized water to remove burrs. The water cannot remove large burrs and may require an tool to follow this process. Electrochemical deburring uses an electrically charged chemical to burn off burrs. The removal of the hazardous chemicals is necessary after this process.