Mass media finishing techniques improve part performance and service life, and these processes can be tailored or modified to amplify this effect. Although the ability of these processes to drive down deburring and surface finishing costs when compared to manual procedures is well known and documented, their ability to dramatically effect part performance and service life are not. This facet of edge and surface finishing deserves closer scrutiny and this is also true of larger and more complex parts – only more so
Convert machined surfaces to plateaued surfDave Davidson
This document discusses various surface finishing techniques for improving part performance and longevity. It describes how traditionally machined surfaces can be unstable under load due to an even distribution of peaks and valleys. Newer plateau honing and polishing techniques allow for controlling peak and valley distributions separately to create stable, load-bearing surfaces. These plateaued isotropic surfaces have been shown to improve properties like lubrication retention, wear resistance, and fatigue life in applications like engine cylinders and gears. The document also introduces turbo-abrasive machining as a newer method that can efficiently produce these improved surfaces on complex parts in a dry, high-speed process.
Centrifugal barrel finishing (CBF) is a high-energy mass finishing process that can produce very refined surfaces on parts in a fraction of the time required by conventional barrel or vibratory finishing. CBF works by mounting barrels on a rotating turret such that as the turret spins, the barrels counter-rotate, subjecting the media and parts inside to high centrifugal forces and sliding motion that quickly remove burrs and create smooth surfaces. CBF is well-suited for precision applications and developing specialized finishes more rapidly than conventional equipment.
This document discusses dry abrasive and polishing media used in mass finishing processes as an alternative to conventional wet processes. It describes how dry media processes avoid the creation and treatment of wastewater but have traditionally been less effective than wet processes due to the lighter weight of dry media. Newer approaches are overcoming this issue through methods like using nylon impregnated with abrasives, high-energy centrifugal equipment, and fixturing parts to increase media contact. The document provides examples of industries using dry processing and highlights advantages like accelerated cycle times and the ability to sequentially process parts to refined surfaces without wastewater.
Turbo-Abrasive Machining in the Continuous Flow Environment Dr Michael Massarsky. Turbo-Finish Corporation, 917 518 8205 michael@turbofinish.com
turbofinish.wordpress.com
Tf 3rd sme international machining conference-rev a-Dave Davidson
This document summarizes a technical paper presented at the 3rd International Machining & Grinding Conference in 1999. The paper introduces Turbo-Abrasive Machining (TAM) and Turbo-Polishing as loose abrasive processes that can efficiently condition surfaces and edges of complex rotating and non-rotating components. TAM uses high-speed rotation of parts in an abrasive fluidized bed to remove burrs and refine surfaces rapidly in single-piece operations. It is presented as an automated alternative to labor-intensive manual deburring that can produce uniform finishes on parts too large or complex for conventional methods. Test results show TAM significantly improves surfaces and increases fatigue life over traditional techniques.
Turbo abrasive machining tech paper - 2016Dave Davidson
INTRODUCTION: Turbo-Finish technology (also referred to as Turbo-Abrasive Machining) is a dry, high-speed spindle finishing process that utilizes abrasive fluidized bed technology, and high speed part rotation to develop extremely rapid and uniform edge and surface conditioning on aerospace, automotive and industrial parts. Polishing, deburring and edge radiusing are accomplished anywhere that the media can access. This finishing technology can develop isotropic surface finishes s while developing consistent round edges on any exposed sharp edged features.
Technical article on Centrifugal Iso-Finishing for deburring and polishing.
Contact:
Dave Davidson
Deburring/Finishing Technologist
SME Tech Community Advisor
dryfinish@gmail.com | 509.230.6821
http://dryfinish.wordpress.com
http://about.me/dave.davidson
http://partsfinished.wordpress.com
Finished part portfolio: https://www.flickr.com/photos/72325472@N04/albums/72157686262863672
________________________
Free Sample Processing
Contract Deburring and Finishing Services
High Energy Finishing Equipment and Process Development
Convert machined surfaces to plateaued surfDave Davidson
This document discusses various surface finishing techniques for improving part performance and longevity. It describes how traditionally machined surfaces can be unstable under load due to an even distribution of peaks and valleys. Newer plateau honing and polishing techniques allow for controlling peak and valley distributions separately to create stable, load-bearing surfaces. These plateaued isotropic surfaces have been shown to improve properties like lubrication retention, wear resistance, and fatigue life in applications like engine cylinders and gears. The document also introduces turbo-abrasive machining as a newer method that can efficiently produce these improved surfaces on complex parts in a dry, high-speed process.
Centrifugal barrel finishing (CBF) is a high-energy mass finishing process that can produce very refined surfaces on parts in a fraction of the time required by conventional barrel or vibratory finishing. CBF works by mounting barrels on a rotating turret such that as the turret spins, the barrels counter-rotate, subjecting the media and parts inside to high centrifugal forces and sliding motion that quickly remove burrs and create smooth surfaces. CBF is well-suited for precision applications and developing specialized finishes more rapidly than conventional equipment.
This document discusses dry abrasive and polishing media used in mass finishing processes as an alternative to conventional wet processes. It describes how dry media processes avoid the creation and treatment of wastewater but have traditionally been less effective than wet processes due to the lighter weight of dry media. Newer approaches are overcoming this issue through methods like using nylon impregnated with abrasives, high-energy centrifugal equipment, and fixturing parts to increase media contact. The document provides examples of industries using dry processing and highlights advantages like accelerated cycle times and the ability to sequentially process parts to refined surfaces without wastewater.
Turbo-Abrasive Machining in the Continuous Flow Environment Dr Michael Massarsky. Turbo-Finish Corporation, 917 518 8205 michael@turbofinish.com
turbofinish.wordpress.com
Tf 3rd sme international machining conference-rev a-Dave Davidson
This document summarizes a technical paper presented at the 3rd International Machining & Grinding Conference in 1999. The paper introduces Turbo-Abrasive Machining (TAM) and Turbo-Polishing as loose abrasive processes that can efficiently condition surfaces and edges of complex rotating and non-rotating components. TAM uses high-speed rotation of parts in an abrasive fluidized bed to remove burrs and refine surfaces rapidly in single-piece operations. It is presented as an automated alternative to labor-intensive manual deburring that can produce uniform finishes on parts too large or complex for conventional methods. Test results show TAM significantly improves surfaces and increases fatigue life over traditional techniques.
Turbo abrasive machining tech paper - 2016Dave Davidson
INTRODUCTION: Turbo-Finish technology (also referred to as Turbo-Abrasive Machining) is a dry, high-speed spindle finishing process that utilizes abrasive fluidized bed technology, and high speed part rotation to develop extremely rapid and uniform edge and surface conditioning on aerospace, automotive and industrial parts. Polishing, deburring and edge radiusing are accomplished anywhere that the media can access. This finishing technology can develop isotropic surface finishes s while developing consistent round edges on any exposed sharp edged features.
Technical article on Centrifugal Iso-Finishing for deburring and polishing.
Contact:
Dave Davidson
Deburring/Finishing Technologist
SME Tech Community Advisor
dryfinish@gmail.com | 509.230.6821
http://dryfinish.wordpress.com
http://about.me/dave.davidson
http://partsfinished.wordpress.com
Finished part portfolio: https://www.flickr.com/photos/72325472@N04/albums/72157686262863672
________________________
Free Sample Processing
Contract Deburring and Finishing Services
High Energy Finishing Equipment and Process Development
This document describes Turbo-Abrasive Machining (TAM), a mechanical deburring and finishing process that uses fluidized abrasive materials. TAM was originally developed for aerospace engine components but can also finish other rotational and non-rotational parts. TAM provides advantages over manual deburring by automating the finishing process. It produces isotropic surfaces through multidirectional abrasive contact and can improve part properties through residual compressive stress and skewness correction. The process involves suspending abrasive grains in a fluidized bed and rotating parts to interface surfaces and edges with the abrasive grains.
Dr. Michael Massarsky stands with a Turbo-Abrasive Machining center called the Model TF-522, which uses a new dry, high-speed horizontal spindle finishing method called Turbo-Finish to deburr and finish aerospace rotating hardware much faster and cheaper than conventional methods. The Turbo-Finish process can rapidly deburr, radius, and surface condition complex parts in minutes instead of hours, with benefits including uniformity, repeatability, compressive stresses that enhance fatigue resistance, and low-temperature material removal without changing the physical characteristics of the metal surface.
This document discusses Turbo-Abrasive Machining (TAM), a loose abrasive finishing process performed by Turbo-Finish Corporation. TAM uses a fluidized bed of abrasive media and part rotation to deburr and produce uniform, isotropic surfaces and edge contours on complex rotating components. TAM improves upon manual deburring by automating the process and producing more consistent results. Testing showed TAM increased the fatigue life of turbine disks by over 2 times compared to conventional deburring and reduced the dispersion of failure cycles.
The document discusses turbo-abrasive machining (TAM) and turbo-polishing processes for deburring and surface finishing of complex metal parts. TAM uses loose abrasive particles to remove burrs and condition surfaces and edges of rotating parts in a continuous flow, addressing challenges with conventional batch processes. TAM can produce refined surfaces rapidly in minutes compared to hours for manual methods. The processes minimize waste streams and facilitate automation. TAM provides a machining-like method for precision finishing that enhances manufacturing flow.
The document discusses turbo-abrasive machining and finishing (TAM), a process that uses rotational movement of parts in a fluidized bed of abrasive media to deburr, condition edges and surfaces, and develop isotropic surface finishes. TAM can process complex geometries rapidly in under two minutes. It leaves surfaces with compressive stresses that improve metal fatigue resistance compared to conventional methods. The process produces uniform, feature-to-feature finishes without wet waste.
INTRODUCTION: The Turbo-Finish process (also referred to as Turbo-Abrasive Machining )imparts beneficial compressive residual stress to edges and surfaces. and as all critical features of the part are processed simultaneously, it can produce a stress equilibrium throughout the entire part. One of the signature advantages of the process is that it is capable of producing peening like metal surface improvement effects, while simultaneously developing isotropic surfaces and deburring and edge-contouring sharp edged features This combination of edge and surface effects can help extend part life on components by mitigating crack propagation.
Surface finishing 3 d printed metal parts - profilomic and areal dataDave Davidson
Centrifugal Isotropic Finishing is a high-intensity surface finishing method that uses high centrifugal forces to quickly produce very refined surfaces and isotropic properties. It multiplies the effects of abrasives on part surfaces, allowing edge and surface finishing to be completed in less than one tenth the time of conventional methods. 3D imaging shows the reduction in surface texture irregularities after centrifugal isotropic finishing.
Turbo-Abrasive Machining (TAM) is a mechanical deburring and finishing process that uses a fluidized bed of abrasive materials to simultaneously finish all surfaces of complex rotating components. TAM automates finishing, improving quality over manual methods while reducing costs. It produces uniform, isotropic surfaces through multidirectional abrasive particle contact at high speeds. TAM is suitable for deburring, contouring, and conditioning a variety of parts too intricate for other mass finishing methods.
Turbo-Finish Technology is a mechanical deburring and finishing method that uses fluidized abrasive materials. It was originally developed for aerospace engine components but can also be used for non-rotating parts. The process finishes parts in a dry operation using horizontal spindles to accommodate multiple parts. It produces smooth, polished surfaces economically using abrasives and rapid spindle speeds. Turbo-Finish is used across industries like aerospace, automotive, and power generation to deburr parts like discs, blades, cutters, and gears.
The document discusses advances in abrasive flow machining (AFM) and orbital abrasive flow machining technologies. AFM uses a semisolid abrasive media to deburr, polish, or radius surfaces by flowing it over target areas. Orbital abrasive flow machining combines AFM with an orbital grinding motion to uniformly remove material from complex shapes. Both techniques can process a variety of materials and have applications in aerospace, automotive, and other industries.
Turbo-Abrasive Machining is an automated mechanical finish method for deburring, edge-contouring and surface finishing complex rotating parts such as those found in the turbine and gear industries
Mass finishing techniques like vibratory deburring and burnishing can improve the performance and service life of aircraft parts. These techniques produce uniform, isotropic surfaces with beneficial compressive stresses. Studies show these finished surfaces increase metal fatigue resistance compared to conventional methods. Mass finishing is also being used on larger aircraft components and is more economical than manual deburring for complex parts. The uniform stress and surfaces produced by mass finishing improve part quality, durability, and consistency over single-point finishing methods.
Sme membership webinar_08.19.15_final-1Dave Davidson
This document provides information about a webinar on isotropic finishing for surface integrity and part performance. The webinar will be presented by Dave Davidson and Jack Clark and will discuss what isotropic surfaces are, how centrifugal isotropic finishing works, and applications of isotropic finishing for bearings, automotive and dental parts, carbide tooling, medical devices, and more. Isotropic finishing can produce non-directional, random surfaces that improve load bearing and reduce failure compared to conventional machined surfaces.
Surface condition impacts part performancweDave Davidson
1) Surface finish and the presence of burrs on aircraft and aircraft engine parts can significantly impact part performance and lifespan by increasing stresses, corrosion, and reducing sealing abilities.
2) Specialized finishing processes are used to remove burrs, round edges, and optimize surface texture in ways that reduce stresses, improve fatigue life, enhance corrosion resistance, and improve sealing of joints.
3) Paying close attention to edge and surface quality is important in aerospace applications due to the potential for catastrophic failure if surfaces are improperly finished or contain defects.
Turbo-Finish and premature fatigue failure prevention and life extension. Turbo-Finish’s unique ability to produce isotropic surfaces on rotating parts can make them much less susceptible to problems associated with crack propagation. Additionally, the elimination of stress risers, and the generation of round edges are used to help extend component life. Rotating parts can especially benefit from the Turbo-Finish process. Disks and other rotating parts can all benefit from this surface and edge conditioning. Highly finished surfaces also tend to pick up less residual contaminants from operations. and smooth isotropic surfaces generate less turbulent air flow across their surfaces. Additionally, the Turbo-Finish process imparts beneficial compressive residual stress. As critical features of the part are processed simultaneously, it can produce a stress equilibrium throughout the entire part. One of the signature advantages of the process is that it is capable of producing peening like metal surface improvement effects, while simultaneously developing isotropic surfaces and deburring and edge-contouring sharp edged features
IRJET- Buckling Behaviour of Cold Formed Steel SectionsIRJET Journal
This document summarizes a research paper that analyzes the buckling behavior of cold-formed steel sections using numerical modeling. It introduces cold-formed steel, its manufacturing process, and failure modes related to buckling. It then describes modeling 5 channel section geometries with and without lips in CUFSM software under simply supported conditions. The results show that distortional buckling only occurred when lips were present, and its effect varied based on the lip position. In conclusion, CUFSM was found to be a reliable free software to analyze buckling behavior of columns through the finite strip method.
Centrifugal Iso-finishing for Additive Manufactured PartsDDaveDavidson
Centrifugal Iso-Finishing is a high-energy, high-quality, high-speed hands-free mechanical method for deburring, finishing and polishing of 3D printed (additive manufactured) parts as well as coventional subtractive manufactured parts. High Centrifugal force is utilized to accelerated process cycle times and make use of smaller dimensioned media to access intricate and complex part shapes. Useful for hand-deburring minimization and for developing low-micro-inch polished surfaces. Centrifugal Iso-Burnishing can be used for developing compressive stress in part surfaces on the order of that achieved by shot peening making parts much more resistant to fatigue failure or fracture. Plateaud or planarized surfaces improve bearing load capacity of cooperating parts with more wear resistance and improved tribological properties. FREE sample part finishing available, Contact Dave Davidson at ddavidson@deburring-techgroup.com. SEE ALSO https://dryfinish.wixsite.com/iso-finish
Turbo-abrasive machining (TAM) is a mechanical deburring and finishing process that uses rotating or oscillating parts within a chamber of fluidized abrasive materials. It was originally developed for complex aerospace engine components but has been applied to many other rotational and non-rotational parts through fixturing. TAM provides fully automated finishing to remove burrs and produce beneficial surface effects in minutes, reducing costs compared to manual methods. The process finishes all surfaces simultaneously with a customized abrasive sequence to efficiently and uniformly condition parts for improved performance and reduced wear.
It's the Finish that Counts. Technical Magazine article reprint.Dave Davidson
A conventionally produced surface (turned, milled,
ground, EDM) is typically Gaussian in nature, that is,
the peak and valley distribution is pretty much equal
in height. This type of surface can be very unstable and
unpredictable when wear and load bearing are considered. The images in Figure 1 demonstrate this type of
surface.
There are many ways to produce plateaued surfaces.
They are varied in approach but all have the ability to
control the surface peak characteristics separately for
the valley characteristics. Methods that are used to improve surfaces for performance and increased service life include centrifugal barrel finishing, turbo-abrasive machining (aka Turbo-Finish) and isotropic micro-finishing with vibratory finishing equipment. For additional technical information and/or elp with free sample part processing contact Dave Davidson at ddavidson@deburring-tech-group.om
This document discusses turbo-abrasive machining (TAM), a mechanical deburring and finishing method that uses a fluidized bed of abrasive materials. TAM was originally developed for aerospace engine components but can also be used for other parts. It provides more uniform results than single-point machining and allows finishing of very complex parts. The document describes the TAM process, which involves rotating a part in an abrasive fluidized bed to remove burrs and contour edges. Process parameters like abrasive size, rotational speed, and time can be varied to achieve different surface finishes and metal removal rates. TAM is capable of deburring complex parts more efficiently than manual methods.
This document describes Turbo-Abrasive Machining (TAM), a mechanical deburring and finishing process that uses fluidized abrasive materials. TAM was originally developed for aerospace engine components but can also finish other rotational and non-rotational parts. TAM provides advantages over manual deburring by automating the finishing process. It produces isotropic surfaces through multidirectional abrasive contact and can improve part properties through residual compressive stress and skewness correction. The process involves suspending abrasive grains in a fluidized bed and rotating parts to interface surfaces and edges with the abrasive grains.
Dr. Michael Massarsky stands with a Turbo-Abrasive Machining center called the Model TF-522, which uses a new dry, high-speed horizontal spindle finishing method called Turbo-Finish to deburr and finish aerospace rotating hardware much faster and cheaper than conventional methods. The Turbo-Finish process can rapidly deburr, radius, and surface condition complex parts in minutes instead of hours, with benefits including uniformity, repeatability, compressive stresses that enhance fatigue resistance, and low-temperature material removal without changing the physical characteristics of the metal surface.
This document discusses Turbo-Abrasive Machining (TAM), a loose abrasive finishing process performed by Turbo-Finish Corporation. TAM uses a fluidized bed of abrasive media and part rotation to deburr and produce uniform, isotropic surfaces and edge contours on complex rotating components. TAM improves upon manual deburring by automating the process and producing more consistent results. Testing showed TAM increased the fatigue life of turbine disks by over 2 times compared to conventional deburring and reduced the dispersion of failure cycles.
The document discusses turbo-abrasive machining (TAM) and turbo-polishing processes for deburring and surface finishing of complex metal parts. TAM uses loose abrasive particles to remove burrs and condition surfaces and edges of rotating parts in a continuous flow, addressing challenges with conventional batch processes. TAM can produce refined surfaces rapidly in minutes compared to hours for manual methods. The processes minimize waste streams and facilitate automation. TAM provides a machining-like method for precision finishing that enhances manufacturing flow.
The document discusses turbo-abrasive machining and finishing (TAM), a process that uses rotational movement of parts in a fluidized bed of abrasive media to deburr, condition edges and surfaces, and develop isotropic surface finishes. TAM can process complex geometries rapidly in under two minutes. It leaves surfaces with compressive stresses that improve metal fatigue resistance compared to conventional methods. The process produces uniform, feature-to-feature finishes without wet waste.
INTRODUCTION: The Turbo-Finish process (also referred to as Turbo-Abrasive Machining )imparts beneficial compressive residual stress to edges and surfaces. and as all critical features of the part are processed simultaneously, it can produce a stress equilibrium throughout the entire part. One of the signature advantages of the process is that it is capable of producing peening like metal surface improvement effects, while simultaneously developing isotropic surfaces and deburring and edge-contouring sharp edged features This combination of edge and surface effects can help extend part life on components by mitigating crack propagation.
Surface finishing 3 d printed metal parts - profilomic and areal dataDave Davidson
Centrifugal Isotropic Finishing is a high-intensity surface finishing method that uses high centrifugal forces to quickly produce very refined surfaces and isotropic properties. It multiplies the effects of abrasives on part surfaces, allowing edge and surface finishing to be completed in less than one tenth the time of conventional methods. 3D imaging shows the reduction in surface texture irregularities after centrifugal isotropic finishing.
Turbo-Abrasive Machining (TAM) is a mechanical deburring and finishing process that uses a fluidized bed of abrasive materials to simultaneously finish all surfaces of complex rotating components. TAM automates finishing, improving quality over manual methods while reducing costs. It produces uniform, isotropic surfaces through multidirectional abrasive particle contact at high speeds. TAM is suitable for deburring, contouring, and conditioning a variety of parts too intricate for other mass finishing methods.
Turbo-Finish Technology is a mechanical deburring and finishing method that uses fluidized abrasive materials. It was originally developed for aerospace engine components but can also be used for non-rotating parts. The process finishes parts in a dry operation using horizontal spindles to accommodate multiple parts. It produces smooth, polished surfaces economically using abrasives and rapid spindle speeds. Turbo-Finish is used across industries like aerospace, automotive, and power generation to deburr parts like discs, blades, cutters, and gears.
The document discusses advances in abrasive flow machining (AFM) and orbital abrasive flow machining technologies. AFM uses a semisolid abrasive media to deburr, polish, or radius surfaces by flowing it over target areas. Orbital abrasive flow machining combines AFM with an orbital grinding motion to uniformly remove material from complex shapes. Both techniques can process a variety of materials and have applications in aerospace, automotive, and other industries.
Turbo-Abrasive Machining is an automated mechanical finish method for deburring, edge-contouring and surface finishing complex rotating parts such as those found in the turbine and gear industries
Mass finishing techniques like vibratory deburring and burnishing can improve the performance and service life of aircraft parts. These techniques produce uniform, isotropic surfaces with beneficial compressive stresses. Studies show these finished surfaces increase metal fatigue resistance compared to conventional methods. Mass finishing is also being used on larger aircraft components and is more economical than manual deburring for complex parts. The uniform stress and surfaces produced by mass finishing improve part quality, durability, and consistency over single-point finishing methods.
Sme membership webinar_08.19.15_final-1Dave Davidson
This document provides information about a webinar on isotropic finishing for surface integrity and part performance. The webinar will be presented by Dave Davidson and Jack Clark and will discuss what isotropic surfaces are, how centrifugal isotropic finishing works, and applications of isotropic finishing for bearings, automotive and dental parts, carbide tooling, medical devices, and more. Isotropic finishing can produce non-directional, random surfaces that improve load bearing and reduce failure compared to conventional machined surfaces.
Surface condition impacts part performancweDave Davidson
1) Surface finish and the presence of burrs on aircraft and aircraft engine parts can significantly impact part performance and lifespan by increasing stresses, corrosion, and reducing sealing abilities.
2) Specialized finishing processes are used to remove burrs, round edges, and optimize surface texture in ways that reduce stresses, improve fatigue life, enhance corrosion resistance, and improve sealing of joints.
3) Paying close attention to edge and surface quality is important in aerospace applications due to the potential for catastrophic failure if surfaces are improperly finished or contain defects.
Turbo-Finish and premature fatigue failure prevention and life extension. Turbo-Finish’s unique ability to produce isotropic surfaces on rotating parts can make them much less susceptible to problems associated with crack propagation. Additionally, the elimination of stress risers, and the generation of round edges are used to help extend component life. Rotating parts can especially benefit from the Turbo-Finish process. Disks and other rotating parts can all benefit from this surface and edge conditioning. Highly finished surfaces also tend to pick up less residual contaminants from operations. and smooth isotropic surfaces generate less turbulent air flow across their surfaces. Additionally, the Turbo-Finish process imparts beneficial compressive residual stress. As critical features of the part are processed simultaneously, it can produce a stress equilibrium throughout the entire part. One of the signature advantages of the process is that it is capable of producing peening like metal surface improvement effects, while simultaneously developing isotropic surfaces and deburring and edge-contouring sharp edged features
IRJET- Buckling Behaviour of Cold Formed Steel SectionsIRJET Journal
This document summarizes a research paper that analyzes the buckling behavior of cold-formed steel sections using numerical modeling. It introduces cold-formed steel, its manufacturing process, and failure modes related to buckling. It then describes modeling 5 channel section geometries with and without lips in CUFSM software under simply supported conditions. The results show that distortional buckling only occurred when lips were present, and its effect varied based on the lip position. In conclusion, CUFSM was found to be a reliable free software to analyze buckling behavior of columns through the finite strip method.
Centrifugal Iso-finishing for Additive Manufactured PartsDDaveDavidson
Centrifugal Iso-Finishing is a high-energy, high-quality, high-speed hands-free mechanical method for deburring, finishing and polishing of 3D printed (additive manufactured) parts as well as coventional subtractive manufactured parts. High Centrifugal force is utilized to accelerated process cycle times and make use of smaller dimensioned media to access intricate and complex part shapes. Useful for hand-deburring minimization and for developing low-micro-inch polished surfaces. Centrifugal Iso-Burnishing can be used for developing compressive stress in part surfaces on the order of that achieved by shot peening making parts much more resistant to fatigue failure or fracture. Plateaud or planarized surfaces improve bearing load capacity of cooperating parts with more wear resistance and improved tribological properties. FREE sample part finishing available, Contact Dave Davidson at ddavidson@deburring-techgroup.com. SEE ALSO https://dryfinish.wixsite.com/iso-finish
Turbo-abrasive machining (TAM) is a mechanical deburring and finishing process that uses rotating or oscillating parts within a chamber of fluidized abrasive materials. It was originally developed for complex aerospace engine components but has been applied to many other rotational and non-rotational parts through fixturing. TAM provides fully automated finishing to remove burrs and produce beneficial surface effects in minutes, reducing costs compared to manual methods. The process finishes all surfaces simultaneously with a customized abrasive sequence to efficiently and uniformly condition parts for improved performance and reduced wear.
It's the Finish that Counts. Technical Magazine article reprint.Dave Davidson
A conventionally produced surface (turned, milled,
ground, EDM) is typically Gaussian in nature, that is,
the peak and valley distribution is pretty much equal
in height. This type of surface can be very unstable and
unpredictable when wear and load bearing are considered. The images in Figure 1 demonstrate this type of
surface.
There are many ways to produce plateaued surfaces.
They are varied in approach but all have the ability to
control the surface peak characteristics separately for
the valley characteristics. Methods that are used to improve surfaces for performance and increased service life include centrifugal barrel finishing, turbo-abrasive machining (aka Turbo-Finish) and isotropic micro-finishing with vibratory finishing equipment. For additional technical information and/or elp with free sample part processing contact Dave Davidson at ddavidson@deburring-tech-group.om
This document discusses turbo-abrasive machining (TAM), a mechanical deburring and finishing method that uses a fluidized bed of abrasive materials. TAM was originally developed for aerospace engine components but can also be used for other parts. It provides more uniform results than single-point machining and allows finishing of very complex parts. The document describes the TAM process, which involves rotating a part in an abrasive fluidized bed to remove burrs and contour edges. Process parameters like abrasive size, rotational speed, and time can be varied to achieve different surface finishes and metal removal rates. TAM is capable of deburring complex parts more efficiently than manual methods.
Technical article reprint on the high-speed and high-intensity and high-quality Centrifugal iso-Finishing method.. The methods used widely on aerospace, motorsports, automotive, medical, dental, orthodontic and jewelry manufactured parts. For additional information contact Dave Davidson at ddavidson@deburring-tech-group.com. Ask about the free sample part finishing program.
See also the technical blog at https://dryfinish.wordpress.com
Centrifugal Iso-Finishing Technical article as seen in Products Finishing mag...Dave Davidson
Centrifugal iso-finishing is a high-speed mass finishing method that can produce very refined surface finishes on parts in short cycle times. It can be used for deburring, contouring edges, and developing surface finishes that improve part performance, integrity, and lifespan. Centrifugal iso-finishing involves processing parts with abrasives or polishing materials under high surface pressure to truncate peaks and create uniformly compressed stresses in the surface. This improves part wear resistance, fatigue resistance, and ability to withstand repeated stresses compared to surfaces finished by conventional methods.
The document discusses how specialized mechanical finishing processes can improve the performance and lifespan of parts and tools subjected to wear, fatigue, or fracture. It explains that common machining leaves surfaces with undesirable properties like positive skewness and directional textures, while specialized processes can produce negatively skewed, isotropic surfaces with compressive residual stresses. One such process, PEGCO Super-Hone, uniformly treats all surfaces and edges to develop these beneficial properties, subtly modifying tools without compromising dimensions and significantly extending tool lifespan. Overall, optimizing factors like smoothness, bearing ratio, skewness, and texture through specialized finishing can dramatically improve parts in demanding applications.
1. Prior to the 1970s, there was little understanding of how the manufacturing process impacted part performance. Failures were increasing costs.
2. The document discusses how traditionally manufactured surfaces can be unstable, while plateaued surfaces produced by mass finishing methods can improve load bearing and lubrication.
3. It provides examples of how plateau honing cylinder bores and gear conditioning processes have improved engine and gear performance and lifetimes by controlling peak and valley surface characteristics. Surface finish design is now recognized as important for part functionality and predictable performance.
This document discusses how isotropic mass finishing processes can improve part performance and service life. It begins by describing how many manufacturers still rely on outdated manual deburring methods instead of considering edge and surface finishing during initial planning. This leads to higher costs when parts fail quality standards due to burrs or surfaces. The document then explains how mass finishing processes can produce uniform, isotropic surface textures with compressive residual stresses. This improves part wear resistance, fatigue life, and consistency compared to directional textures from machining. Specifically, isotropic mass finishing can produce negatively skewed, plateaued surfaces instead of positively skewed surfaces from other processes. It concludes that these surface alterations from mass finishing often improve part performance in unexpected ways.
This document discusses the benefits of isotropic mass finishing for improving surface integrity and part performance. It describes how many manufacturers still rely on outdated manual deburring and finishing methods instead of considering these processes during initial engineering and planning. This can lead to high costs when parts fail quality standards due to surface issues. The document advocates for including isotropic mass finishing solutions, such as barrel, vibratory, and centrifugal finishing, earlier in the design process to reduce costs and improve part consistency, edge contour, surface smoothness, and performance.
This document discusses advanced finishing processes including abrasive flow machining (AFM), magnetic abrasive finishing (MAF), and magnetorheological abrasive finishing. It focuses on describing the AFM and MAF processes. For AFM, it covers the process mechanisms, equipment types, process parameters and monitoring, applications in industries like aerospace and automotive, advantages, and limitations. For MAF, it describes the process principles, magnetic abrasive mixes, types of MAF, experimental setup and results, advantages in producing nanoscale finishes with few defects, and applications in non-ferromagnetic materials and precision components.
This presentation contain discription about Fine finishing process of complex shape material which cannot be finished by normal processess. three type of finishing process has been described they are Abrasive flow machining, MAgnetic Abrasive Finishing, Magneto Rheological abrasive finishing.
The document discusses two advanced fine finishing processes: abrasive flow machining (AFM) and magnetic abrasive finishing (MAF). It provides details on the process, principles, equipment, parameters, applications and advantages of AFM, which can achieve surface finishes down to 50 nm. AFM is widely used in aerospace, automotive and medical industries to improve surfaces. The document also introduces magnetic abrasive finishing, which uses magnetic fields to control abrasive particles and achieve high-precision finishing of complex internal surfaces down to the nanometer range.
ABRASIVE BASED NANO FINISHING TECHNIQUES AN OVERVIEW.pdfAayushRajput4
This document provides an overview of abrasive-based nano-finishing techniques. It discusses traditional finishing processes like grinding and honing and their limitations. It then introduces advanced finishing processes like abrasive flow machining, magnetorheological finishing, magnetic abrasive finishing, and chemo mechanical polishing which can produce surfaces with roughness in the nanometer range. The document focuses on magnetic abrasive finishing and discusses how using a pulsed DC power supply with the electromagnet can substantially increase the finishing rate by creating a pulsating flexible magnetic abrasive brush. It also discusses how online measurement of forces has helped understand the material removal mechanism during static and pulsating magnetic abrasive finishing.
The document describes Turbo-Abrasive Machining (TAM), a dry finishing process that uses horizontal spindles and a fluidized abrasive bed to deburr and finish complex rotating components. TAM produces isotropic surfaces with beneficial compressive stresses. It is an automated alternative to manual deburring that reduces cycle times and eliminates wastewater. TAM can process parts as small as 2 inches or as large as 48 inches in diameter for industries such as aerospace, power generation, automotive, and others.
Surface condition impacts part performancweDave Davidson
1) Surface finish and the presence of burrs on aircraft and aircraft engine parts can significantly impact part performance and lifespan by increasing stresses, corrosion, and reducing sealing abilities.
2) Specialized finishing processes are used to remove burrs, round edges, and optimize surface texture in ways that reduce stresses, improve fatigue life, enhance corrosion resistance, and improve sealing of joints.
3) Paying close attention to edge and surface quality is important in aerospace applications due to the potential for catastrophic failure if surfaces are improperly finished or contain defects.
Centrifugal Iso-Finishing for Additive Manufactured PartsDave Davidson
Centrifugal Iso-Finishing Technology is used on 3D Printed and conventional CNC precision machined components for deburring, finishing and polishing. It is a high-speed, high-quality hands-free finishing method that produces highly refined surface finishes in a fraction of the time required by other equipment (10 times faster, in many cases) Free sample finishing of your parts is available, contact Dave Davidson at ddavidson@deburring-tech-group.com
General Dynamics uses various mechanical deburring and finishing processes for sheet metal and machined parts to meet demanding aerospace industry standards in a cost-effective manner. For sheet metal, they use rotating disc and cylinder machines for single-pass deburring. For machined parts, they use robotic deburring with brushes, deburring on machine tools in a Flexible Machining System, and a slurry finishing system. They are developing new automated systems like a two-table brush machine and a combined robot/vision/flow-through finishing system to further reduce labor costs, though much finishing still requires manual work.
The document discusses the future of mass finishing and centrifugal barrel finishing technology. It describes traditional finishing methods like wire wheels and vibratory bowls as inconsistent and costly. Centrifugal barrel finishing offers superior performance at significantly lower costs. It can maintain tight tolerances, produce smooth finishes, and efficiently remove burrs. The technology uses rotating barrels to impart precise forces on media and parts, offering more control and flexibility than other methods. It is effective for a wide range of materials, part sizes, and surface finishing needs.
The document discusses several advanced nano finishing processes, focusing on abrasive flow machining (AFM). It provides an overview of AFM, explaining the working principles, equipment, process parameters, applications, advantages, and limitations. Specifically, it describes the one-way, two-way, and orbital AFM processes. It discusses the material removal mechanisms in AFM and how surface finish is improved. The document also briefly introduces magnetic abrasive finishing (MAF) and magneto rheological abrasive finishing, defining their basic concepts and differences from AFM.
Centrifugal Iso-Finishing is a high-speed, high-quality and hands-free method for deburring, smoothing, surface-0finishing, burnishing and polishing of work-pieces and parts. Contact Dave Davidson for additional technical information and assistance with getting your parts sample finished. Contact me at ddavidson@deburring-tech-group.com See also dryfinish.wordpress.com
Modern machine-shop-apr-18 centrifugal isofinishing crnakshaftsDave Davidson
See the technical article on Centrifugal Iso-Finishing on surface finish and it's effect on engine components in the Motorsports Industry terms of performance improvement.
Contact D. A. (Dave) Davidson at ddavidson@deburring-tech-group.com for additional information or help with free sample finishing.
Iso-Finishing sample part finishing application formDave Davidson
Free sample part processing and quotations for deburring, finishing or polishing of your production parts.
(1) Download the Word document form into your computer.
(2) Complete the form and include a paper copy with your sample parts to being shipped to the Isofinishing address shown on the form
MFI full finishing product catalog with technical assistance infoDave Davidson
Mass Finishing Equipment and Supply Catalog includes equipment, finishing media, supplies and accessories. Features Centrifugal Iso-Finishing equipment for high-speed and hands-free deburring, finishing and polishing. For technical assistance and help with arranging for free sample finishing of your parts contact Dave Dagvidson at ddavidson@deburring-tech-group.com
Modern machine shop interviews Dave Davidson about Gear finishing processes. For additional technical information and assistance with sample part finishing contact Dave Davidson | ddavidson@deburring-tech-group.com # #machining #polishing #finish #cnc #manufacturingengineering #automotiveindustry #finishing #deburring #leanmanufacturing #aerospace #massfinishing #grinding #automotive #leanmaufacturing #gears
BV PRODUCTS - Bowl and Tub Vibratory Finishing SystemsDave Davidson
Vibratory finishing machines designed, engineered and built-in Australia that out-perform and out-last vibratory finishing machines costing much more.
Robust design with direct-drive motor and integrated parts/media separation for economical vibratory finishing of metal parts. BV Products has been perfecting its unique all cast polyurethane vibratory finishing machines with direct-drive motion generators for almost 40 years to make them the most innovative and most cost-effective surface finishing solution in the industry. Contact Dave Davidson: ddavidson@deburring-tech-group.com
BV PRODUCTS VIBRATORY FINISHING SYSTEMS FOR DEBURRING AND FINISHINGDave Davidson
Vibratory finishing machines designed, engineered and built-in Australia that out-perform and out-last vibratory finishing machines costing much more.
Robust design with direct-drive motor and integrated parts/media separation for economical vibratory finishing of metal parts. BV Products has been perfecting its unique all cast polyurethane vibratory finishing machines with direct-drive motion generators for almost 40 years to make them the most innovative and most cost-effective surface finishing solution in the industry. Contact Dave Davidson: ddavidson@deburring-tech-group.com
BV Products - Vibratory Finishing machinery for deburring and polishingDave Davidson
Vibratory finishing machines designed, engineered and built-in Australia that out-perform and out-last vibratory finishing machines costing much more.
Robust design with direct-drive motor and integrated parts/media separation for economical vibratory finishing of metal parts. BV Products has been perfecting its unique all cast polyurethane vibratory finishing machines with direct-drive motion generators for almost 40 years to make them the most innovative and most cost-effective surface finishing solution in the industry. Contact Dave Davidson: ddavidson@deburring-tech-group.com
Vibratory finishing machines designed, engineered and built in Australia that out-perform and out-last vibratory finishing machines costing much more. Robust design with direct-drive motor and integrated parts/media separation for economical vibratory finishing of metal parts. BV Products has been perfecting its unique all cast polyurethane vibratory finishing machines with direct-drive motion generators for almost 40 years to make them the most innovative and most cost-effective surface finishing solution in the industry. Contact Dave Davidson: ddavidson@deburring-tech-group.com
Centrifugal iso finishing sample processingDave Davidson
High-Speed, Hands-free deburring, iso-finishing and polishing of manufactured and 3D printed parts. Contact Dave Davidson for free sample finishing, technical assistance and contract deburring and iso-finish polishing at dryfinish@gmail.com | https://dryfinish.wixsite.com/iso-finish https://lnkd.in/gFjetZk
Centrifugal iso finishing contract services Dave Davidson
High-Speed, Hands-free deburring, iso-finishing and polishing of manufactured and 3D printed parts. Contact Dave Davidson for free sample finishing, technical assistance and contract deburring and iso-finish polishing at dryfinish@gmail.com | https://dryfinish.wixsite.com/iso-finish https://lnkd.in/gFjetZk
This document discusses high-speed post-processing of 3D printed parts using centrifugal iso-finishing to speed up workflows and reduce bottlenecks. It invites contacting the sender to arrange running sample parts through their free surface finishing program to see how it improves the process.
Centrifugal iso finishing - part dividersDave Davidson
High-Speed, Hands-free deburring, iso-finishing and polishing of manufactured and 3D printed parts. Contact Dave Davidson for free sample finishing, technical assistance and contract deburring and iso-finish polishing at dryfinish@gmail.com | https://dryfinish.wixsite.com/iso-finish https://lnkd.in/gFjetZk
Final vibratory iso-finishing processesDave Davidson
High-Speed iso-finishing and polishing of manufactured and 3D printed parts. Contact Dave Davidson for free sample finishing, technical assistance and contract deburring and iso-finish polishing at dryfinish@gmail.com | https://dryfinish.wixsite.com/iso-finish https://lnkd.in/gFjetZk
High-Speed, Hands-free deburring, iso-finishing and polishing of manufactured and 3D printed parts. Contact Dave Davidson for free sample finishing, technical assistance and contract deburring and iso-finish polishing at dryfinish@gmail.com | https://dryfinish.wixsite.com/iso-finish https://lnkd.in/gFjetZk
Centrifugal iso finishing - Equipment descriptionDave Davidson
High-Speed, Hands-free deburring, iso-finishing and polishing of manufactured and 3D printed parts. Contact Dave Davidson for free sample finishing, technical assistance and contract deburring and iso-finish polishing at dryfinish@gmail.com | https://dryfinish.wixsite.com/iso-finish
https://lnkd.in/gFjetZk
Centrifugal iso finishing - how it worksDave Davidson
High-Speed, Hands-free deburring, iso-finishing and polishing of manufactured and 3D printed parts. Contact Dave Davidson for free sample finishing, technical assistance and contract deburring and iso-finish polishing at dryfinish@gmail.com | https://dryfinish.wixsite.com/iso-finish https://lnkd.in/gFjetZk
Super-finishing or CASF is a process that produces a very smooth finish on metal surfaces to reduce contact stresses and friction. It works by applying a reactive chemistry in a vibratory machine along with ceramic media to create a soft coating on the peaks and valleys of a component's surface. The rubbing motion removes micro layers of metal from the peaks, leaving a mirror-like surface without affecting the component's integrity or dimensions. This super-fine finish improves components' performance across many industries by mitigating the effects of friction, heat, vibration and fatigue.
Centrifugal iso finishing for High-Performance SurfacesDave Davidson
High-Speed, Hands-free deburring, iso-finishing and polishing of manufactured and 3D printed parts. Contact Dave Davidson for free sample finishing, technical assistance and contract deburring and finishing at dryfinish@gmail.com | https//about.me/dave/davidson | See the videos at https://dryfinish.wordpress.com
CONTACT: Dave Davidson
Debuuring/Finishing Technologist
dryfinish@gmail.com | 509.230.6821
https://partsfinished.wordpress.com
Vibratory Finishing SME Tech Paper John Kittredge Dave Davidson
This document discusses vibratory deburring processes. It defines what a burr is and categorizes burrs by degree. It explains how the vibratory finishing industry approaches deburring problems by selecting the appropriate equipment, media, and process parameters based on the part geometry and deburring requirements. Examples of successful deburring applications across different industries are provided to illustrate the wide scope of vibratory deburring.
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In the rapidly evolving landscape of technologies, XML continues to play a vital role in structuring, storing, and transporting data across diverse systems. The recent advancements in artificial intelligence (AI) present new methodologies for enhancing XML development workflows, introducing efficiency, automation, and intelligent capabilities. This presentation will outline the scope and perspective of utilizing AI in XML development. The potential benefits and the possible pitfalls will be highlighted, providing a balanced view of the subject.
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1. October 2013 | ManufacturingEngineeringMedia.com 1
T
urbo-Abrasive Machining (also referred to
as TAM or Turbo-Finish) is a mechanical
deburring and finishing method originally
developed to automate edge finishing
procedures on complex rotationally oriented
and symmetrical aerospace engine compo-
nents. Aerospace parts such as turbine and compressor
disks, fan disks and impellers pose serious edge finishing
problems. Manual methods used in edge finishing for
these parts were costly and time-consuming. What’s
more, human intervention, no matter how skillful at this
final stage of manufacturing, was bound to introduce
some measure of non-uniformity in both effects and
stresses in critical areas of certain features on the part.
Free Abrasives Flow
for Automated Finishing
Exploring new methods of surface finishing
that go beyond deburring to specific isotropic
surface finishes that can increase service life
Dr. Michael L. Massarsky
Turbo-Finish Corporation
David A. Davidson
SME Manufacturing
Deburring/Finishing Tech Group
Deburring & Finishing
In Turbo-Abrasive Machining, a broad, low-speed airstream is used to
impart motion to powdered or granular material within a chamber.The
material, typically small aluminum oxide grains, takes on the properties
of and behaves like a fluid. In this example, the fluidized bed partially
envelops a rotating workpiece, creating a specific abrasive environment
for a certain level of deburring and finishing.
2. Since its inception, turbo-abrasive machining, a method
that utilizes fluidized abrasive materials, has facilitated signifi-
cant reductions in the amount of manual intervention required
to deburr large components. Additionally, the process has also
proved to be useful in edge and surface finishing a wide vari-
ety of other nonrotational components by incorporating these
components into fixturing systems.
The advantages of this method go beyond the simple
removal or attenuation of burrs. The method is also capable of
producing surface conditions at these critical edge areas that
contribute to increased service life and functionality of parts
that are severely stressed in service. Among these advantages
are (1) the creation of isotropic surfaces, (2) the replacement of
positively skewed surface profiles with negative or neutral skews
and (3) the development of beneficial compressive stress.
Deburring, Finishing, Part Performance and Productivity
Deburring and surface conditioning of complex machined
parts is one of the most troublesome problems faced by the
metalworking industry. In many cases, parts with complex
geometric forms that are machined, or manufactured with
very sophisticated computer-controlled equipment, are then
deburred, edge finished, and surface conditioned with manual
or hand-held power tools. This labor-intensive manual han-
dling often has a considerable negative impact on manufac-
turing process flow, productivity, and uniformity of features as
well as part-to-part and lot-to-lot uniformity.
The workflow interruption and production bottlenecks
that can result are frequently one of the most significant
headaches that manufacturing managers must confront. The
total costs involved in performing manual finishing often defy
quantification. As these types of processes are seldom capital
intensive, they frequently escape the budget scrutiny they de-
serve. Additionally, it is becoming increasingly clear that edge
and surface finish effects can now be produced on parts that
contribute substantially to their performance as well as wear
and fatigue resistance values.
TAM Advantages
TAM processes were developed primarily for automating de-
burring and surface conditioning procedures for complex rotat-
ing components. As an automated machining/finishing process,
TAM is designed to address the uniformity and productivity
concerns noted above. Repetitive motion injury problems can
be minimized or eliminated as manual methods are replaced
with automated machining procedures. Substantial quality and
uniformity improvements can be made in precision parts as the
art in manual deburring is removed and replaced with the sci-
ence of a controllable and repeatable machining sequence. The
time and cost of having substantial work-in-progress delays,
production bottlenecks, nonconforming product reviews, rework
and scrap can be reduced dramatically. Manual processes
consuming many hours are reduced to automated machining
cycles of only a few minutes.
Fluidized Bed Technology in Action
TAM machines could be likened to free abrasive turning
centers. They utilize fluidized bed technology to suspend
abrasive materials in a specially designed chamber. Parts
interface with granular abrasive material on a continuous
basis by having part surfaces exposed and interacted with the
fluidized abrasive bed by high-speed rotational or oscillational
movement. This combination of abrasive envelopment and
high-speed rotational contact can produce important func-
tional surface conditioning effects and deburring and radius
formation very rapidly.
Unlike buff, brush, belt and polish methods or even
robotic deburring, abrasive operations on rotating components
are performed on all features of the part simultaneously. This
produces a feature-to-feature and part-to-part uniformity
that is almost impossible to duplicate by any other method.
Surface finishes and effects can be generated on the entire
2 ManufacturingEngineeringMedia.com | October 2013
Deburring & Finishing
This broach slot area of a turbine disk has been turbo-abra-
sive machined and then turbo-polished to remove burrs
and produce edge-contour with isotropic surfaces,specifi-
cally at the edge-area,but generally on the disk itself.
PhotocourtesyDr.MichaelMassarsky,Turbo-FinishCorporation
3. exterior of complex parts, and also fixtured nonrotational
components. Various surface-finish effects can be obtained
by controlling variables of the process such as rotational part
speed, part positioning, cycle times, abrasive particle size and
characteristics, and others.
Surface-finish effects in TAM are generated by the high
peripheral speed of rotating parts and the large number and in-
tensity of abrasive particle-to-part surface contacts or impacts in
a given unit of time (200–500 per mm²/sec). It should be noted
that surface-finish effects developed from this process depart
October 2013 | ManufacturingEngineeringMedia.com 3
Deburring & Finishing
T
his before photograph above was taken with a scanning electron
microscope at 500× magnification. It shows the surface of a raw
unfinished “as cast” turbine blade. The rough initial surface finish as
measured by profilometer was in the 75–90 Ra
(µin.) range. As is typical of
most cast, ground, turned, milled, EDM and forged surfaces this surface
shows a positive Rsk
[Rsk
–skewness–the measure of surface symmetry about
the mean line of a profilometer graph. Unfinished parts usually display
a heavy concentration of surface peaks above this mean line, generally
considered to be an undesirable characteristic from a functional viewpoint.]
This SEM photomicrograph (500× magnification) above was taken
after processing the same turbine blade in a multistep procedure
utilizing orbital pressure methods with both grinding and polishing free
abrasive materials in sequence. The surface profile has been reduced
from the original 75–90 Ra
(µin.) to a 5–9 Ra (µin.) range. Additionally,
there has been a plateauing of the surface and the resultant smoother
surface manifests a negative skew (Rsk
) instead of a positive skew. This
type of surface is considered to be very “functional” in both the fluid
and aerodynamic sense. The smooth, less turbulent flow created by this
type of surface is preferred in many aerodynamic applications. Another
important consideration the photomicrographs indicate is that surface
and subsurface fractures seem to have been removed. Observations
with backscatter emission with a scanning electron microscope gave no
indication of residual fractures.
Surface Characterization with Optical Interferometry.
Surface topographical mapping is coming into increasing use to bet-
ter quantify surfaces as they relate to part service life, function and
performance. The surface shown in the top row is one that has been
processed to blend in parallel rows of surface peaks left behind from
fine grinding operations (as shown in the bottom row of diagrams).
The resultant surface is one that is more isotropic or random in nature.
This type of surface can be an important surface attribute to parts
that are subjected to repeated stress or strain and parts that undergo
high force loading of opposing surfaces. Also contributing to the
improved functional surface is the negative skew of the surface profile
and beneficial compressive stress equilibrium imparted to the parts by
high-energy finishing methods.
Understanding Functional Surfaces
Photo courtesy Jack Clark, Surface Analytics
Photo courtesy Jack Clark, Surface Analytics
4. significantly from those obtained from air or wheel blasting. TAM
processes can produce much more refined surfaces by virtue of
the fact that the rotational movement of parts processed develop
a very fine finish pattern and a much more level surface profile
than is possible from pressure and impact methods.
A very important functional aspect of TAM technology is
its ability to develop needed surface finishes in a low-temper-
ature operation (in contrast with conventional wheel and belt
grinding methods), with no phase shift or structural changes
in the surface layer of the metal. A further feature of the
process is that it produces a more random pattern of surface
tracks than the more linear abrasive methods such as wheel
grinding or belt grinding. The nonlinear finish pattern that
results often enhances the surface in such a way as to make it
much more receptive as a bonding substrate for subsequent
coating and even plating operations.
TAM Applications
TAM provides a method whereby final deburring, radius
formation and blending in of machining irregularities could be
performed in a single machining operation. This operation can
accomplish in a few minutes what in many cases took hours
to perform manually. It has become obvious that the tech-
nology could address edge-finishing needs of other types of
rotationally oriented components such as gears, turbocharger
rotors, bearing cages, pump impellers, propellers, and many
other rotational parts. Nonrotational parts can also be pro-
cessed by fixturing them to the periphery of disk-like fixtures.
Many larger and more complex rotationally oriented parts,
which can pose a severe challenge for conventional mechani-
cal finishing methods, can easily be processed.
TAM as a surface-conditioning method is a blend of
current machining and surface-finishing technologies. Like
machining processes the energy used to remove material from
the part is concentrated in the part itself, not the abrasive
material interfacing with part surfaces, and like many surface-
finishing processes material removal is not accomplished by
a cutting tool with a single point of contact, but by complete
envelopment of the exterior areas of the part with abrasive
materials. As a result deburring, edge finishing, surface blend-
ing and smoothing, and surface conditioning are performed
on all exterior exposed surfaces, edges, and features of the
part simultaneously. Many metal parts that are machined by
being held in a rotational workholding device (for example:
chucks, between centers, rotary tables, etc.) are potential
candidates for TAM processes, and in many cases these
final deburring and surface conditioning operations can be
performed in minutes, if not in seconds.
TAM Processing Characteristics
TAM produces an entirely different and unique surface
condition. One of the reasons for this is the multidirectional
and rolling nature of abrasive particle contact with part sur-
faces. Unlike surface effects created with pressure or impact
methods such as air or wheel blasting, TAM surfaces are
characterized by a homogeneous, finely blended, abrasive
pattern developed by the nonperpendicular nature of abrasive
attack. Unlike wheel or belt grinding, surface finishes are gen-
erated without any perceptible temperature shift at the area
of contact and the micro-textured random abrasive pattern
is a much more attractive substrate for subsequent coating
operations than linear wheel or belt grinding patterns. TAM
processes have strong application on certain types of parts
that have critical metal surface improvement requirements of
a functional nature. Significant metal surface integrity and im-
provement has been realized in processes with both abrasive
and nonabrasive media. As a result of intense abrasive par-
ticle contact with exposed features, it has been observed that
residual compressive stresses of up to 400–600 MPa can be
created in selected critical areas. Tests performed on rotating
parts for the aerospace industry that were processed with this
4 ManufacturingEngineeringMedia.com | October 2013
Deburring & Finishing
To see Turbo-Abrasive Machining in action, check out
The Metal Shop at Manufacturing Engineering’s
YouTube channel: www.tinyurl.com/mfgmetalshop
This Model TF-522 Turbo-
Abrasive Machining
Center is designed for
deburring and edge
contour of rotating
hardware up to 20"
(+500 mm).
5. method demonstrated a 40–200% increase in metal fatigue
resistance tested under working conditions, when compared
with parts that had been deburred and edge finished with less
sophisticated manual treatment protocols.
Significant process characteristics to keep in mind include
(1) very rapid cycle times; (2) a high-intensity, small media
operation that allows for access into intricate part geometries;
(3) a completely dry operation; (4) metal surface improvement
effects: including isotropic, negatively skewed surfaces with
improved bearing load ratio and contact rigidity (5) no part-
on-part contact; (6) modest tooling requirements; (7) primarily
an external surface preparation method some simpler interior
channels can also be processed, and (8) many types of rotating
components can be processed and non-rotational components
can also be processed when attached to disk like fixtures. ME
October 2013 | ManufacturingEngineeringMedia.com 5
Deburring & Finishing
TURBO-FINISH
Ph: 917-518-8205
Web site: www.turbofinish.com
Want More Information?
In this view,Turbo-Abrasive Machining has been performed,
edge contour has been developed, and isotropic surfaces
are evident in the flats visible between the slots.The
previous surface condition can also be seen on the
surface area closer to the center which was masked by
the processing tooling.