Meeting the Lean Deburring Challenge SOCIETY OF MANUFACTURING ENGINEERS David A. Davidson; Michael Massarsky Ph.D; Jack ClarkDeburring, Edge-Finish, Surface Conditioning Technical Group Lean2Green Resource Center EASTEC – Springfield MA May 20, 2009
Meeting the Lean Deburring Challenge Terry Begnoche, SME Manager for Lean Activities and Programming adjusts microphone clip for Dave Davidson, SME DESC Group Chair at the SME Lean2Green Conference Program area
Batch and Queue –Typical Hand DeburrStage 1 - Production in Functional Departments A B C
Batch and Queue Hand Deburring atMacKay before Lean Deburringimplementation with Centrifugal
Meeting the Lean Deburring Challenge This presentation ws developed with materials provided by members of the Deburring, Edge and Surface Conditioning Technical Group. One of the technical committees that comprise the Technical Community Network of the Society of Manufact- uring Engineers. A major focus of the Society in recent years has been to proliferate LEAN by providing resources as well as educational and certification opportunities for those who wish to utilize LEAN in their production and business processes. This presentation was developed to highlight how LEAN and mass finishing technologies can be meshed….
Continuous Flow Stage 4 - Compact Cell w/One-Piece Flow & Separation Member & Machine A B C
High pressure, high force processingwith small media replaces batch andqueue hand processing.
Deburring Cell – visual aid Competency at a glance
Visual Aids – tracking the high mix –low volume flow of critical and premiumparts at MacKay Manufacturing
Turbo 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 – Lean Deburring Dr. Michael Massarsky (below) inventor of the Turbo-Abrasive Machining method which promotes rapid, single piece continuous flow deburring of large complex rotational parts
Turbo Abrasive Machining Basics Lean Deburring, Lean Finishing Free abrasive method uses fluidized bed and part rotational forces • 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
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.
Turbo Abrasive Machining – Lean Deburring Michael Massarsky Ph D. Inventor of the Turbo-Finish method . In a “lean” context his process has brought single piece continuous flow processing capability to deburring and edge finish challenges on large rotating parts in the aerospace industry. Additionally, the method has shown to improve service life on critical aerospace hardware. One jet engine manufacturer found its hardware life was improved by 50% in rigorous spin pit testing…
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
Understanding Part Performance: Current Condition vs. Target Condition Dave Davidson and Jack Clark, SME members involved with the Deburring and Edge/Surface Conditioning Technical Group
Understanding Part Performance: Current Condition vs. Target Condition As Cast After Centrifugal Finish As ground After Centrifugal Finish High Magnification electron microscope photos – before and after
Jack Clark of Surface Analytics is a nationally recognized authority on surface metrologyand the understanding of surface characterization relationships to part performance andlongevity. Jack became interested in surface finish for performance when as a leader of aFormula One Racing Team , he could extend the life of critical engine hardware from onerace to a year. Using electron microscopes and optical interferometry Jack assistsmanufacturers develop surface finishes that provide dramatic increases in service life.
Out from underneath the Microscope Parts processed with Lean Finishing…