Lean Deburringwith Turbo-Abrasive

Finishing

Lean Deburringwith Turbo-Abrasive

Finishing

SOCIETY OF MANUFACTURING ENGINEERSby Michael Massarsky Ph.D; President

Turbo-Finish CorporationMichael@Turbofinish.com

Basic Turbo-Finish PrinciplesBasic Turbo-Finish Principles

Spindle run time effects contour developmentSpindle run time effects contour development

Edge contour – simultaneous and identical produces stress equilibrium…Edge contour – simultaneous and identical produces stress equilibrium…

Disk feature improvement Disk feature improvement

Before and After example – Turbo-Finish produces isotropic surface finishBefore and After example – Turbo-Finish produces isotropic surface finish

BEFORE and AFTER – Burr Removal and Isotropic surface generationBEFORE and AFTER – Burr Removal and Isotropic surface generation

BEFORE and AFTER -- Burr Removal and edge contour generation.

BEFORE and AFTER -- Burr Removal and edge contour generation.

Burr Removal from Drilled Burr Removal from Drilled

Turbo-Finish Radius Generation ChartTurbo-Finish Radius Generation Chart

Radius development on dove tail slotsRadius development on dove tail slots

Edge contour development on rotor styled partsEdge contour development on rotor styled parts

Planetary fixturing for turbine blade finishingPlanetary fixturing for turbine blade finishing

Disk slot features before Turbo-Abrasive MachiningDisk slot features before Turbo-Abrasive Machining

Edge finish after processingEdge finish after processing

Profilometer readings showing surface profile reduction.Profilometer readings showing surface profile reduction.

LEAN Rapid Edge Contour – Isotropic Finish of Large Rotational Aerospace Components with TAM

Turbo Abrasive Machining technology replaces batch and queue hand deburr with LEAN cellular machining concept.

Drives down defect rate to near zero. Drives down WIP from hours to minutes in single piece continuous flow

Turbo Abrasive Machining – Lean DeburringTurbo Abrasive Machining – Lean Deburring

This machine was built to deburr and edge-contour turbine and compressor disks up to 20 inches in diameter [500mm]

Turbo Abrasive Machining Basics Lean Deburring, Lean FinishingTurbo Abrasive Machining Basics Lean Deburring, Lean Finishing

• Fluidized bed technology develops complete envelopment of parts with loose abrasive

• Rotational movement of parts produces high intensity abrasive particle contact with part edges and surfaces to develop edge contour and surface finish

• Relatively small media and high speed rotation promote processing of intricate or complex geometries and even simple interior channels

Free abrasive method uses fluidized bed and part rotational forces

INDUSTRY: Aerospace

PART: Turbine; Compressor Disks

PROBLEM: Reduce deburring timeand cost; develop edge-contour, develop isotropic surfaces, develop compressive stress

PROCESS(ES) REPLACED:hand-tools; pencil grinders

TURBOFINISH SOLUTION:Implement TAM Process withTF-Turbo-Abrasive Machine

TURBOFINISH PROCESS IMPROVEMENT:10 inch disk processing time reduced from 3 hrs to 3 min. Per part abrasive cost reduced to 0.15 each.20 inch disk processing time reduced from 3-10 hrs to 6 min.

Turbo Abrasive Machining Basics Lean Deburring Case Study

TAM vs. Manual Deburring – Service Improvement, fatigue resistance TAM vs. Manual Deburring – Service Improvement, fatigue resistance

Also, destructive testing of steel plates:

Conventional ground plates fail after (1.1 – 1.5) * 104 cyclesTAM process plates fail after (3 – 3.75) * 104 cycles

COMPARISONS:

Fatigue Limit Value σ_1

Grinding = 250 + 43 MPa

TAM = 330 + 20 Mpa

Spin Test Results: (cycles)Disks with Manual treatment

Cracks appear: 2600 + 700

Disks destruct: 5685 + 335

Disks with TAM treatment

Cracks appear: 7300 + 700

Disks Destruct: 13090 + 450

IMPORTANTTAKE AWAYPOINT

Understanding Part Performance: Current Condition vs. Target ConditionUnderstanding Part Performance: Current Condition vs. Target Condition

Typical Cast Surface Typical Isotropic Surface

Typical Ground Surface Typical Isotropic Surface