Experimental Optimization of Abrasive Brush Deburring for Burr Control at Window–Hole Intersections

Abrasive brushing is widely adopted for edge finishing in automotive manufacturing, yet burr removal remains unreliable at window–hole intersections where a cast ADC12 aluminum skin meets drilled features. At these cast–machined interfaces, microstructure heterogeneity (eutectic Si morphology, intermetallic particles, and casting porosity) and local strength/ductility gradients promote fused burr roots, edge serration, and micro-crack initiation during high-pressure water-jet (HPWJ) cleaning, making residual burrs persistent particle sources. This study develops a materials-informed abrasive brush deburring framework for stable removal of window-intersection burrs in ADC12 transmission components. Burr formation and failure modes at cast–drilled edges are first analyzed to explain why HPWJ and nylon brushing can trigger erosion, smearing, and secondary debris. Brushing kinematics and tool–burr interactions are then quantified, and a Taguchi L8 design optimizes six parameters (filament diameter, rotation speed, feed rate, repetitions, and bidirectional dwell times) using a smaller-the-better S/N criterion. Burr height is measured at eight window locations via high-resolution optical microscopy and conoscopic holography. Abrasive filaments outperform nylon, particularly for feed-direction and fused burrs, with rotation speed and filament diameter as dominant factors. Under optimized conditions, the hybrid HPWJ–abrasive brushing route achieves sub-10 μm local burr height while preserving edge integrity and limiting micro-crack growth and surface damage. The results link process parameters to cleanability-relevant materials outcomes, providing practical guidance for clean manufacturing of aluminum transmission and hydraulic components. It improves tool life through controlled filament wear. • Establishes a unified framework linking burr formation, deburring, and automotive cleanliness requirements • Identifies window-intersection burrs as critical contamination sources in automotive transmission components • Evaluates limitations of HPWJ and nylon brushing in terms of surface damage, smearing, and particle generation • Applies Taguchi design to identify key process parameters governing industrial deburring performance • Demonstrates a hybrid brushing strategy achieving sub-10 μm burr height with improved edge integrity and reduced contamination risk