Improving Perfor mance and Life of Aerospace Engine Har dware by Developing Isotropic Surfaces with Turbo-Abrasive Machining SOCIETY OF MANUFACTURING ENGINEERSAERODEF Conferenc005e, Long Beach. CA Mar 20, 2013 Dr. Michael Massarsky; President, Turbo-Finish Corporation. 25 Williamsville Road, Barre, Massachusetts 01005 (e) firstname.lastname@example.org (t) 917.518.8205
Turbo Abrasive Machining – Lean Deburring This abrasive fliudized bed machining center is capable of processing 20 inch (500mm) disks
Turbo Abrasive Machining Basics Lean Deburring Case Study INDUSTRY: Aerospace PART: Turbine; Compressor Disks PROBLEM: Reduce deburring time and cost; develop edge-contour, develop isotropic surfaces, develop compressive stress PROCESS(ES) REPLACED: hand-tools; pencil grinders TURBOFINISH SOLUTION: Implement TAM Process with TF-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.
TAM vs. Manual DeburringService Improvement, fatigue resistance 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 IMPORTANT Also, destructive testing of steel plates: TAKE AWAY Conventional ground plates fail after (1.1 – 1.5) * 104 cycles POINT TAM process plates fail after (3 – 3.75) * 104 cycles
LEAN Rapid Edge Contour – Isotropic Finish ofLarge 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
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