Hy-Pro, based at Dawlish on Devon's coast, has built a good reputation for its own range of secondary steerage systems for boats which have seen extensive use in the Southern Ocean where only the simplest, most efficient systems survive the harsh and unrelenting conditions.

Over the years the introduction of multi axis CNC has produced the expected increase in quality and reduction in time, however burrs still remain an issue. They are just now smaller and more inaccessible. They still cause the same problems though; a reduction in the speed and quality of assembly, causing surface damage, jams, seal wear and premature failure.

Hy-Pro's solution had been 100% inspection and 100% manual deburring. Both very time consuming and allowing inconsistencies. A more automated approach was sought.

Thermal deburring had been considered a number of years earlier and quickly dismissed when aluminium manifolds and valve blocks were returned exploded and gears came back melted. Despite trying various process, their failure to find a reliable solution prompted them to reassess thermal and approach Deburring Centre. The Poole-based company was able to explain why past encounters with thermal processes had failed and successfully trailed a few parts to prove
the process.

"Thermal deburring has revolutionised our manufacturing of 22 mm diameter gears," explained Kevin Saunders, Hy-Pro's production manager. "We were hand deburring 56 edges on our 14 tooth gears. Which was time consuming, brain numbing and variable to say the least. Thermal deburring has automated the process, given a higher, guaranteed quality level, maintains our 5 micron tolerance level far better and, on top of all that, actually saves us money.

"I'm now feeling very confident with the subcon process and enjoy knowing it's a safe, done deal. It has made my life so much easier.

"The removal of fine, internal, whisker burrs in our aluminium and cast iron blocks will be the next procedure we look at."