industrial processes ii industrial processes ii inden 3313 lecture 4 – completion of finishing;...
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Industrial Processes II
INDUSTRIAL PROCESSES IIINDUSTRIAL PROCESSES II
INDEN 3313INDEN 3313
Lecture 4 – Completion of Lecture 4 – Completion of Finishing; Treatments, Finishing; Treatments, Coatings, and CleaningCoatings, and Cleaning
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Industrial Processes II
OVERVIEWOVERVIEW
• Return of HomeworkReturn of Homework• Questions to Start/ErrataQuestions to Start/Errata• FinishingFinishing
– Process Descriptions– Parameters/Impact on Surface Finish
• TreatmentsTreatments• CoatingsCoatings• CleaningCleaning
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Industrial Processes II
QUESTIONSQUESTIONSTO START ??TO START ??
Errata --Errata --
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Industrial Processes II
HONINGHONING• IllustrationIllustration
Groover Figure 26.19, p 675
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Industrial Processes II
HONINGHONING• Comparison to GrindingComparison to Grinding
– Universal Joints Enable Stone to “Follow the Hole”• Highest Pressure/Abrasion at Smallest
Diameters– Precision Hole Size, Finish
• Center Compliance Assured, Cross Hatched Pattern – Hold Lubrication in Hole
– Process Parameters• Abrasive Material• Grit Size• Pressure Used• Adhesive Used (Bond)• Hone Speed
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Industrial Processes II
LAPPINGLAPPING• IllustrationIllustration
Kalpakjian, Figure 25.31, p.815
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Industrial Processes II
LAPPINGLAPPING• Comparison to GrindingComparison to Grinding
– Both Lap and Work Move (Same Grain Never in Same Location on Workpiece• Abrasives in Slurry
– Low Pressure– Able to Move in Response to Cutting Forces
– Process Parameters• Abrasive Material• Grit Size• Slurry Consistency• Lap/Work Speed
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Industrial Processes II
POLISHINGPOLISHING
• DescriptionDescription
– Fine Abrasive Powders Are Used to Coat Fabric, Leather, Felt, … Disks or Belts
– Coated Disk or Belt Rubbed on Surface to be Finished
– Fine Abrasives Remove Material
– Friction Heating Softens and Smears Surface Layers
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Industrial Processes II
POLISHINGPOLISHING• Comparison to GrindingComparison to Grinding
– Very Soft Backing Material (Cloth)– Fine Abrasives (May be in Slurry)– Low Pressure
– Process Parameters• Abrasive Material• Abrasive Particle Size• Backing Material• Pressure Used
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Industrial Processes II
BUFFINGBUFFING• DescriptionDescription
– Similar to Buffing with Softer Backing and/or Softer and/or Finer Abrasives
– Also Known as “Compounding” from the term “Buffing Compound”
– Extremely Fine Surface Finish Obtainable
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Industrial Processes II
BUFFINGBUFFING• Comparison to GrindingComparison to Grinding
– Very Soft Backing Material (Cloth)– Very Fine Soft Abrasives (May be in
Slurry)– Low Pressure
– Process Parameters• Abrasive Material• Abrasive Particle Size• Backing Material• Pressure Used
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Industrial Processes II
ELECTRO-POLISHINGELECTRO-POLISHING• DescriptionDescription
– Placement of Workpiece in Electrolytic Solution
– Application of Electrical Potential to Workpiece
– Ions (Charge) Collects on Outer Surface of Part
– Ions Go Into Solution (Dissolve)– Highest Surface Goes Into Solution
Most Rapidly
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Industrial Processes II
ELECTRO-POLISHINGELECTRO-POLISHING• Comparison to GrindingComparison to Grinding
– Removal of Material via Electro-Chemical Means (NOT Shearing/Metal Cutting)
– Process Parameters• Electrolyte Used• Strength of Potential (Voltage)• Duration of Applied Potential
– Can Use a Similar Process With Metal Grinding Wheel – Grinding Fluid is Electrolyte and Known as Electro Chemical Grinding
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Industrial Processes II
FLOAT POLISHINGFLOAT POLISHING• IllustrationIllustration
Kalpakjian, Figure 25.32, p.816
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Industrial Processes II
FLOAT POLISHINGFLOAT POLISHING• Comparison to GrindingComparison to Grinding
– Pressure Supplied by Magnetic Forces• Magnetic (Metallic Abrasives) Pulled Onto
Workpiece Via Strength of Magnetic Field• Permanent or Electro-Magnets Used• Used on Ceramic Ball Bearings• Pioneered at OSU
– Process Parameters• Abrasive Material• Grit Size, Slurry• Strength of Magnetic Field• Rotational Speed
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Industrial Processes II
BARREL FINISHINGBARREL FINISHING• DescriptionDescription
– Parts and (Dry Pellets) Abrasive are Placed into a Container
– Container is Rotated– As Container Rotates the Parts
Shift/Slide Against One Another (with the Abrasive Between Them) and the Weight of the Parts Provides the Pressure for the Abrasion Process.
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Industrial Processes II
BARREL FINISHINGBARREL FINISHING• IllustrationIllustration
Groover, Figure 32.2, p. 816
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Industrial Processes II
BARREL FINISHINGBARREL FINISHING• Illustration Of Pellet ShapesIllustration Of Pellet Shapes
Groover, Figure 32.3, p. 817
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Industrial Processes II
BARREL FINISHINGBARREL FINISHING• Comparison to GrindingComparison to Grinding
– Lower Pressure– Slower Speeds– Shaped (Loose) Abrasives
– Process Parameters• Abrasive Material• Abrasive Pellet Shape• Ratio of Parts to Abrasive• Rotational Speed
– Also Known as “Tumbling”
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Industrial Processes II
• IllustrationIllustration
Kalpakjian, Figure 25.33, p.818
ABRASIVE FLOWABRASIVE FLOW
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Industrial Processes II
ABRASIVE FLOWABRASIVE FLOW• Comparison to GrindingComparison to Grinding
– Lower Pressure– Slower Speeds– Abrasive Slurry
– Process Parameters• Abrasive Material• Abrasive Slurry “Stiffness”• Pressure Forcing Slurry Through/Around
Part
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Industrial Processes II
ABRASIVE JETABRASIVE JET• IllustrationIllustration
Kalpakjian, Figure 26.20, p.847
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Industrial Processes II
ABRASIVE JETABRASIVE JET• Comparison to GrindingComparison to Grinding
– “Soft” Backing (Air)– Small Depths of Cut (Bounce Off)– Abrasive is “Loose”– Peens Surface
– Process Parameters• Abrasive Material• Abrasive Particle Size and Shape• Angle of Incidence
– Also Known as Sand Blasting, Bead Blasting
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Industrial Processes II
SURFACE TREATMENT SURFACE TREATMENT AND COATINGAND COATING
• GoalsGoals– Improve Hardness (Wear Resistance)– Reduce Adhesion– Improve (Retention) of Lubricants– Improve Corrosion Resistance
• Barrier Methods• Insulation Methods
– Improve Fatigue Resistance– Build-up/Restore Worn Surfaces– Modify Surface
• Smoother or Rougher• Color
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Industrial Processes II
SURFACE TREATMENTSURFACE TREATMENT• DefinitionDefinition
– Changes Metallurgy (Crystalline Structure) of Metallic Parts Using Pressure or Heat
• TypesTypes– Mechanical (Cold Working)
• Shot Peen/Hammer Peening– Hit Surface with Ceramic or Steel Shot or Hammer
• Roller/Ball Burnishing– Use Surface Rollers to Plastically Deform Surface
• Explosive Hardening– Use High, Transient Force Application to Cold
Work Surface
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Industrial Processes II
SURFACE TREATMENTSURFACE TREATMENT• TypesTypes
– Thermal• Flame and Induction Hardening
– No Material Added, Smaller Grains at Surface– Heat and then Cool Surface/Part– Usually an “Air Quench” Process
• Anneal– Heat/ Soften Surface via Annealing– Often Done in Furnace
• Case Hardening– Material Added, Carburizing, Nitriding, ... – Heat To Assist in Diffusion into Surface then
Cool Surface– Parameters
» Temperature, Time, Pressure
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Industrial Processes II
COATINGSCOATINGS• DefinitionDefinition
– Processes which Add Materials to the Base Component(s)
• TypesTypes– Mechanical (Apply Particles onto
Surface)• Cladding
– Roll Thin Layer onto Base Metal (Alclad, Zn Coated Steel
• Mechanical Plating– “Throw” Metal Particles/Powder onto Surface
» Analogy – Snow Ball onto a Brick Wall
• Painting
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Industrial Processes II
COATINGSCOATINGS• Types (cont.)Types (cont.)
– Thermal (Coat w/Molten Material)• Thermal Spraying (Metallizing)
– Liquid Metal Spray Produced by Combustion/Heating to Melt Metal in Nozzle and use Escaping Gas to Expel Molten Metal at Speed onto (cool) Surface.
– Parameters/Concerns» Temperature, Gas , Gas Pressures» Oxydation (vacuum)
– Done at OKC Air Logistics Center to Rebuild Worn Jet Engines
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Industrial Processes II
COATINGSCOATINGS• Types (Cont.)Types (Cont.)
– Thermal• Hard Facing
– Harder Material Added to Surface – Melt a Filler Rod onto a Surface Rather Using
an Electric Arc or Oxyfuel Heat Source– Often, Some Melting of Base Surface
• (Hot) Dipping– Dip part to be Coated in Molten Metal– Galvanization (Zn Coating)
• Enameling (Coat and Fuse with Heat)– Enameling of Steels, …– Glazing of Ceramics
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Industrial Processes II
COATINGSCOATINGS• Types (cont.)Types (cont.)
– Physical Vapor Deposition• Vacuum Evaporation
– Evaporate metal to be deposited at high temperature
– Let condense on cool part– Uniform Coating (Simple and Complex
Shapes)– Parameters
» Temperature Difference, Exposure Time
• Sputtering– Use of ionized inert gas to bombard cathode,
causing sputtering (ejection) of its atoms and subsequent condensation of the metal atoms on anode
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Industrial Processes II
COATINGSCOATINGS• Types (cont.)Types (cont.)
– Chemical Vapor Deposition• Thermochemical process – a reaction
produces desired coating in an inert atmosphere – TiN Coating of Cutting Tools
– Chemical• Electroplating, Plating, Electroforming
– Deposition of ions from solution onto base» Electroplating, Electrical Current Used» Plating, No Current – Uses Reduction Reaction» Electroforming, Current, No Base Metal Coated
– Parameters» Current Density, Voltage, Time» Part Shape (Affects Uniformity of Coating)
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Industrial Processes II
COATINGSCOATINGS• TypesTypes– Chemical (cont.)
• Anodizing (Oxidizing Aluminum)– Produces porous oxide (hard) layer on surface
via emersion of electrolytic cell in acid bath -- oxygen adsorption by metal – can add color (dyes)
• Conversion Coating (Surface Reactions)– Naturally occurring oxides are formed on
surfaces via chemical or electrochemical reactions; colors can be produced from some reactions (black oxides on iron steels)
• Sol-Gels– OSU Research on corrosion resistance for
aging aircraft
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Industrial Processes II
CLEANINGCLEANING• DefinitionDefinition
– Removal of Contaminants from Surfaces• Dirt, Oils, Moisture, …
• TypesTypes– Mechanical
• Brushing (Wire)• Blasting (Abrasive Jet)• Tumbling• Steam• Ultrasonic
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Industrial Processes II
CLEANINGCLEANING
• TypesTypes– Chemical
• Solution (Dissolves Dirt into Solution)• Saponification (Convert Oils to Soap)• Emulsification (Suspend in Emulsion)• Dispersion (Reduce Concentration, Dilute)• Aggregation (Collect Particles, Remove
Collection)• Pickling (Acid or Alkaline to Dissolve)
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Industrial Processes II
QUESTIONSQUESTIONSOR OR
CLARIFICATIONCLARIFICATIONS ???S ???