Improving Perfor mance and Life of Aerospace Engine Har dware by Developing Isotropic Surfaces with Turbo-Abrasive Machining SOCIETY OF MANUFACTURING ENGINEERSAERODEF Confecrence, Long Beach. CA Mar 9, 2013Dr. Michael Massarsky; President, Turbo-Finish Corporation. David A. Davidson, Technical Group Chair Deburring, Edge-Finish, Surface Conditioning Technical Group Machining/Metal Removal Technical Community
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
Centrifugal Barrel Finishing – High IntensitySurface Finishing in a non-fixtured environment • High Speed Processing • Quick-change over • High-Mix, Low Volume capability
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
Out from underneath the Microscope Parts processed with High Intensity Finishing…
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…
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
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
Jack Clark of Surface Analytics is a nationally recognized authority on surface metrology andthe 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.