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Turbo Abrasive Finishing


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Turbo Abrasive Finishing

  1. 1. Lean Deburring with Turbo-Abrasive Finishing SOCIETY OF MANUFACTURING ENGINEERS by Michael Massarsky Ph.D; President Turbo-Finish Corporation [email_address]
  2. 2. Basic Turbo-Finish Principles
  3. 3. Spindle run time effects contour development
  4. 4. Edge contour – simultaneous and identical produces stress equilibrium…
  5. 5. Disk feature improvement
  6. 6. Before and After example – Turbo-Finish produces isotropic surface finish
  7. 7. BEFORE and AFTER – Burr Removal and Isotropic surface generation
  8. 8. BEFORE and AFTER -- Burr Removal and edge contour generation.
  9. 9. Burr Removal from Drilled
  10. 10. Turbo-Finish Radius Generation Chart
  11. 11. Radius development on dove tail slots
  12. 12. Edge contour development on rotor styled parts
  13. 13. Planetary fixturing for turbine blade finishing
  14. 14. Disk slot features before Turbo-Abrasive Machining
  15. 15. Edge finish after processing
  16. 16. Profilometer readings showing surface profile reduction.
  17. 17. LEAN Rapid Edge Contour – Isotropic Finish of Large 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
  18. 18. 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]
  19. 19. Turbo Abrasive Machining Basics Lean Deburring, Lean Finishing <ul><li>Fluidized bed technology develops complete envelopment of parts with loose abrasive </li></ul><ul><li>Rotational movement of parts produces high intensity abrasive particle contact with part edges and surfaces to develop edge contour and surface finish </li></ul><ul><li>Relatively small media and high speed rotation promote processing of intricate or complex geometries and even simple interior channels </li></ul>Free abrasive method uses fluidized bed and part rotational forces
  20. 20. 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 Basics Lean Deburring Case Study
  21. 21. TAM vs. Manual Deburring – Service Improvement, fatigue resistance Also, destructive testing of steel plates: Conventional ground plates fail after (1.1 – 1.5) * 10 4 cycles TAM process plates fail after (3 – 3.75) * 10 4 cycles 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 TAKE AWAY POINT
  22. 22. Understanding Part Performance: Current Condition vs. Target Condition Typical Cast Surface Typical Isotropic Surface Typical Ground Surface Typical Isotropic Surface