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Localized stress increases because of burrs, causing cracks to form as well as part failure in worst case scenarios.
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Fatigue life is reduced due to the crack propagation and additional wear and tear caused by the presence of burrs.
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Damage to fasteners and reduction of the efficacy of fasteners due to uneven seating surfaces being present as a result of the burrs.
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Elastomer and sealing element damage caused by burrs found in internal groove geometries. This damage can lead to increased safety hazards are seals prevent over pressurization, chemical leaks, and gas evacuation.
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Increased corrosion failure. As cracks and crevices are formed by burrs, catch points for chemicals that can erode material strength become present and hold onto corrosive liquids that would have otherwise slid off the part.