turbo abrasive machining and finishing

Turbo-Abrasive Machining and

FinishingSME MMR ISOTROPIC SURFACE FINISH RESEARCH PROJECT

Dr. Michael Massarsky | TURBOFINISH CORP. | [email protected]

David A. Davidson | SME MMR Tech Community | [email protected]

1

mailto:[email protected]


Turbo-Abrasive Machining and Finishing TAM BASICS

Fluidized bed technology develops complete

envelopment of parts with free abrasive media

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

A wide variety of abrasive and polishing media

can be utilized from heavy abrasives

topolishing media for developing low micro-

inch surfaces

SME MMR Isotropic Surface Finish Research Project

Dr. Michael Massarsky | TURBOFINISH CORP. | [email protected] A. Davidson | SME MMR Tech Community | [email protected]

2



Turbo-Abrasive Machining and Finishing

Turbo-Finish Applications

Deburring, Edge and Surface Conditioning,

Metal Improvement

Turbine and Compressor Disks

Rotational Oriented Static Hardware

Gears, Impellers, Rotors, Sprockets, Turnings

Automotive: Piston Rings; Turbocharger

rotors

Textile, Pump, Marine Industry rotating parts

Non-Rotating Parts with disk fixturing



3



Turbo-Abrasive Machining and Finishing Significant Process Characteristics

Rapid machine cycles replace tedious manual processes

Intricate part geometries accessed (small media – high intensity rolling or glancing contact)

Completely DRY abrasive, polishing or non-abrasive operation, NO WET WASTE DISPOSAL

Micro-textured surfaces are excellent substrate for coatings

Metal surface improvement; compressive stress effects, enhanced metal fatigue resistance

No part-on-part contact or impingement Disk prior to TAM processing



4




Significant Process Characteristics

Rapid simple operation well suited to single piece continuous flow and cell operations

Very modest tooling requirements

Primarily external edge and surface conditioning method. Some simple interior work possible.

Both rotating and fixtured non-rotating parts can be processed.

Isotropic surfaces generated

Feature-to-feature, part-to-part and lot-to-lot uniformity not achievable with manual methods Disk after TAM Processing



5



Turbo-Abrasive Machining and Finishing Significant Process Characteristics

HORIZONTAL SPINDLE OPERATION

Multiple parts can be fixtured on a single spindle

Unique abrasive delivery system (fluidized bed) assures uniform processing of all parts on the spindle

The abrasive fluidized bed permits high-speed rotational operation. Speeds of 800- 2000 rpm are commonly specified.

The takt time (floor-to-floor) for running these disks was calculated to be 60 seconds

Multiple part operation



6





Smaller diameter parts can also be run in

multiple spindle equipment

These rotor parts were run in a dry abrasive process in an eight spindle machine.

Takt time per part (floor to floor) was 38

seconds

Multiple spindle operation



7





Small media operation permits process to access difficult geometries

Small dry abrasive media can reach intricate details that poses a problem for larger performed media shapes common to other types of mass finishing operations.



8





Significant radius and edge-contour developed on slot areas of aerospace turbine and compressor engine disks



9





Rotationally oriented parts are fixtured and clamped at the end of a spindle and rotated around the spindle axis

Non-rotational parts are processed by fixturing the part on disk-like holding fixtures



10




PROCESS CONTROLLED VARIABLES

Rotational Speed

Time

Surface roughness pattern orientation to vector

Abrasive particle size

Abrasive composition

SME MMR Isotropic Surface

Finish Research Project


11




HIGH-SPEED and RAPID:

Deburring

Edge-Contour

Isotropic Surface Development

Compressive Stress Equilibrium

Surface plateauing or planarization for converting positively skewed machined surfaces to negatively skewed surfaces



12




HIGH-SPEED and RAPID PROCESSING:

Edge-Contour effects are often developed in 60 – 120 second cycles



13




BEFORE and AFTER COMPARISON

Edge-Contour and Isotropic Surfaces are often developed in 60 –120 second cycles

SME MMR Isotropic Surface Finish

Research Project


14




BEFORE and AFTER

COMPARISON

Rapid deburring and

material removal



15




BEFORE and AFTER

COMPARISON



16




COMPARISON

Improvement seen in metal fatigue limit and contact rigidity over conventional methods



17




METAL IMPROVEMENT

TAM processing produced superior metal fatigue resistance by developing a compressive stress equilibrium in the disk components

Conventional machined surfaces were converted to isotropic surfaces by blending in machining marks or notches that are potential crack propagation points



18




SEQUENTIAL

PROCESSING

Secondary operations

include processing with

dry polishing media to

produce refined

surfaces to better

facilitate visual

inspection

SME MMR Isotropic Surface

Finish Research Project

Dr. Michael Massarsky | TURBOFINISH CORP. |

[email protected] A. Davidson | SME MMR Tech Community | [email protected]

19



turbo abrasive machining and finishing

Engineering

turboabrasive machining

dry abrasive

abrasive fluidized bed

michael massarsky turbofinish

wide variety of abrasive

surface conditioning

complete envelopment

small media high intensity