The document outlines a proposed study by the Deburring, Edge-Finish, Surface Conditioning Technical Group of the SME to test how edge conditioning through centrifugal barrel finishing affects tool life and part quality in milling. The study would select a common part and milling operation, document tool edge radii and surfaces before and after conditioning, conduct life tests with conditioned and unconditioned tools, document tool and part measurements, and publish a report of findings. The goals are to confirm that edge conditioning improves tool life, speeds, surface finish, and prevents wear-related part defects over time. Participating organizations would supply tools, conditioning, machining, analysis, and organization.

1. Deburring, Edge-Finish, Surface
Conditioning Technical Group
SME Tooling/Cutter Edge Radius Study Project
Submitted by Jack R. Clark, Surface Analytics, LLC
and Colorado State University, Mechanical Engineering Dept
16 March 2011
1. Background
1.1. For many decades there has been an
awareness of cutting tool edge condition and
tool surface finish and the effect it has on
piece part quality and tool life. There have
been many independent studies, tests, and
implementations of edge conditioning
methods to create extended life in turning,
drilling, and milling cutter tooling - some
published but most kept “secret” as a
manufacturing advantage.
1.2. The “Deburr/Finish Tech Group” of the SME
has tasked itself to manage the project and
use it’s member resource pool to provide
tooling, applications, and the necessary
documentation and reporting to objectively
test cutting tool edge radius improvement on
tool life and piece part consistency. This is a
proposed outline on how to organize and
conduct such a test. It is the intention of the
participants to publish a document, possibly
an SME Technical paper or article, at the
conclusion of the study.
2. Goals
2.1. Confirm that edge and finish conditioning
improves tooling life and potentially also improves performance values in tool speed,
feed speed and substrate surface finish and helps prevent part surface finish
deterioration from tool wear over extended periods of time.
3. Proposed participants
3.1. Mackay Manufacturing - supply the test tooling, machine a selection of piece parts,
and gather tool life and piece part data.
3.2. Mass Finishing, Inc. - supply the finishing process(s) to condition the tooling for
testing.
3.3. Machining Efficiencies, Inc. - consult on test format, measurands, and result analysis.
3.4. Dave Davidson - SME liaison, general test organization, processing advise.
Project Contact Information:
Jack Clark
Surface Analytics, LLC
Correspondence: PO Box 71
Shipping: 8543 North County
Road 27
Masonville, CO 80541
Cell: 860.575.7500
Fax: 832.575.7504
jclark@surfaceanalytics.com
Jack Clark (2)
Colorado State University
Department of Mechanical
Engineering
1374 Campus Delivery
Fort Collins, CO 80523-1374
Office: 970.491.4382
jack.clark@colostate.edu
Dave Davidson
Deburrinnng Solutions
7609 N. Hughes Drive
Spokane WA 99208
Cell: 509 230 6821
dryfinish@gmail.com
http://www.linkedin.com/in/ddavidsondeburr

2. Deburring, Edge-Finish, Surface
Conditioning Technical Group
3.5. Surface Analytics - general test organization, tooling and piece part documentation,
processing advise, results analysis
4. Proposed Tasks
4.1. Select a known, repeated “high volume” piece part
4.2. Select a milling operation that has tool usage history and is typically consistent in tool
life
4.3. Select the milling tooling
4.4. Document “as supplied” tooling condition
4.4.1. edge radius at predetermined positions
4.4.2. surface finish at predetermined positions
4.4.3. all dimensional characteristics critical to tool performance
4.5. Centrifugal Barrel Finish (CBF) the tooling
4.5.1. establish process parameters
4.5.2. process the test tooling
4.6. Document “finished” tooling condition
4.6.1. edge radius at predetermined positions
4.6.2. surface finish at predetermined positions
4.7. Perform “Life” tests on tooling
4.7.1. determine what machining parameters will be monitored
4.7.2. run “as supplied” tooling as a test control
4.7.3. run “finished” tooling tests
4.7.4. save all tooling whether failed or not for documentation
4.7.5. save a sampling of piece parts for documentation
4.8. Document “all” post machining tooling condition
4.8.1. edge radius at predetermined positions
4.8.2. surface finish at predetermined positions
4.8.3. all dimensional characteristics critical to tool performance
4.9. Document all piece parts
4.9.1. finish
4.9.2. defects
4.9.3. dimensional
4.10. Complete “Tooling Test Summary” spread sheet - see attached (Appendix A)
4.11. Complete the “Edge Radius Study” report including:
4.11.1. piece part drawing(s) indicating the surface(s) and profile(s) being machined by
the test tooling
4.11.2. test tooling part number(s), supplier(s), and specifications
4.11.3. list all tooling documentation methods, setups, and callouts measured
4.11.4. list all CBF setups and process conditions
4.11.5. list all machine tool setups, conditions, and observations