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.
For additional information CONTACT Dave Davidson | dryfinish@gmail.com | https://en.gravatar.com/dryfinish
Wherever metals come into contact with each other contact stresses and friction occur. Both these conditions regulate and reduce the performance and compromise the design.
of the component. Super-finishing or CASF (Chemically Accelerated Surface Finishing) is a means of regaining those losses by producing a superfine finish where it is most needed.
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
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.
For additional information CONTACT Dave Davidson | dryfinish@gmail.com | https://en.gravatar.com/dryfinish
Wherever metals come into contact with each other contact stresses and friction occur. Both these conditions regulate and reduce the performance and compromise the design.
of the component. Super-finishing or CASF (Chemically Accelerated Surface Finishing) is a means of regaining those losses by producing a superfine finish where it is most needed.
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
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
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
Turbo-Abrasive Machining in the Continuous Flow Environment Dr Michael Massarsky. Turbo-Finish Corporation, 917 518 8205 michael@turbofinish.com
turbofinish.wordpress.com
GMT started manufacturing lapping & polishing machine in 1971. It was built for in-house use and until then hand lapping process was used for finishing surface plates. Critical parts for our workholding devices required a finishing and buffing machine. There was demand in the market for valve lapping and lapping plates. Since GMT had a captive ferrous foundry, castings for lap plate and lapping machine were easier to source.
Since then GMT has become one of India's largest lapping machine manufacturers and suppliers with over 350 installations throughout India mainly to the valve and pump industry. When a buyer in Japan wanted a super finishing machine for lapping large granite plates, GMT designed and supplied a 3000mm dia flat lapping machine.
Pump manufacturers, electronic industries, valve manufacturers, etc., have found a sure way of obtaining positive sealing.
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
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
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
Turbo-Abrasive Machining in the Continuous Flow Environment Dr Michael Massarsky. Turbo-Finish Corporation, 917 518 8205 michael@turbofinish.com
turbofinish.wordpress.com
GMT started manufacturing lapping & polishing machine in 1971. It was built for in-house use and until then hand lapping process was used for finishing surface plates. Critical parts for our workholding devices required a finishing and buffing machine. There was demand in the market for valve lapping and lapping plates. Since GMT had a captive ferrous foundry, castings for lap plate and lapping machine were easier to source.
Since then GMT has become one of India's largest lapping machine manufacturers and suppliers with over 350 installations throughout India mainly to the valve and pump industry. When a buyer in Japan wanted a super finishing machine for lapping large granite plates, GMT designed and supplied a 3000mm dia flat lapping machine.
Pump manufacturers, electronic industries, valve manufacturers, etc., have found a sure way of obtaining positive sealing.
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
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 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
This high-speed, high-intensity mass finishing
method can improve part performance. Centrifugal iso-finishing can be used not only for deburring and edge-contour, but also to
develop surface finish attributes that improve the performance,
surface integrity and service life of components.
A High-Speed, High-Energy Alternative
Centrifugal iso-finishing is a high-speed and high-intensity
mass finishing method in which abrasive or polishing materials are caused to interact with part edges and surfaces
with 10 times the surface pressure of low-energy finishing
methods. What this means, in practical terms, is that it is
possible to produce very refined surface finishes in abbreviated process cycle times. It also means that parts with
complex and detailed geometries can be deburred with a
minimum of manual intervention.
Piston in the internal combustion (IC) engine is robust, dynamically loaded tribo-pair that
reciprocates continuously at varying temperature. Study has been made by various researchers on piston
design, dynamics, fatigue and wear at the interface with other element in contact along with their effects on
IC engines. It was found that the friction coefficient increases with increasing surface roughness of liner
surface and thermal performance of the piston increases with increased coating thickness. The free material
liberated due to deep scoring between the piston and liner snowballs, leads to seizure failure.
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 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
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
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 - 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
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
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
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Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
1. 1
Prior to the early 1970s, there was little to no
awareness of the relationship between part function and
the process that created a piece part. Many areas of
automotive power train manufacturing were starting to
realize that component failure was causing increases in
scrap and warranty costs even though the used
metallurgy, fit, and form were specified and controlled
properly. There was no unified understanding of the
root cause of premature wear, leakage, noise, unusually
high operating temperatures, and catastrophic failure, or
even if they were related.
DEFINITIONS 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
can control the surface peak characteristics separately
for the valley characteristics. This is summarized in
Figure 2, showing that the peak and valley distributions
can be controlled to allow substantial bearing load
capabilities (broad, flat areas) with well-defined
lubrication, debris collecting valleys.
Engine Cylinder Bores: Honing cylinder bores
produce an evenly distributed (Gaussian) surface of
peaks and valleys. Lubrication (lube) retention is
dependent on the valley portion of the surface, allowing
even distribution over the entire swept area of the piston
and rings. Contrary to that, the peak portion of the
surface was not supporting the needs of other bore
requirements, such as reducing friction, sealing to the
piston ring, and reduction of wear. As extended
warrantee life (now over 100,000 miles in diesel
applications), emission requirements, and higher
combustion temperatures evolved, the need for more
control of the surfaces became evident. Plateau honing
was first used as a final cylinder bore finishing
technique in the 1970s. Later (1980’s), the diesel
industry was instrumental in incorporating this
technique to extend engine life and improve the sealing
Figure 1: Typical positively skewed surface common to
most grinding and machining operations. (Courtesy of
Jack Clark, Surface Analytics, Ft Collins, CO.)
Figure 2: Plateaued surface as typical of surface
conditioning produced by a variety of mass finishing
methods. (Courtesy of Jack Clark, Surface Analytics, Ft
Collins, CO.)
Jack Clark
Surface Analytics, LLC
Fort Collins, CO 80526
phone: 860.575.7500
email: jclark@surfaceanalytics.com
Dr. Michael L Massarsky
TURBOFINISH CORPORATION
P. O. Box 344
Barre, MA 01005 USA
phone; 917.518.8205
e-mail: michael@turbofinish.com
David A. Davidson
SME Technical Community Network,
Colville, WA 99114 USA
phone: 509.230.6821
e-mail: dryfinish@gmail.com
Edge and Surface Conditioning for Improved Part
Performance and Service Life
INTRODUCTION: When presented with edge and surface finishing problems,
many manufacturers continue to reach for solutions that rely on out-of-date, time-
consuming and labor-intensive methods. It is still not unusual to see precision parts
and critical hardware being manually handled and edge and surface finishing
operations being performed with abrasive hand tools, or manually controlled power
tools that utilize coated abrasives or abrasive filaments. This situation often arises
from insufficient planning and a lack of understanding what will be required to
render the manufactured part or component acceptable for consumer use or end-
user application. The authors discuss the importance of understanding mass
finishing methods, not only as economical methods to automate finishing processes,
but also as an important strategy for improving overall part functional performance
and service life.
2. 2
of the piston ring to the bore. Today, the gasoline engine
manufacturers are finding that they must migrate to
these bore conditioning practices to meet emission
requirements and, again, extend predictable engine life.
The solution has been in respecifying bore materials
and implementing new honing techniques. The old
standard of cast iron was a material that did not support
finely controlled machining processes. Consistently,
there were issues with tears and folds in the surfaces,
poor plateau, and frictional characteristics.
Manufacturers have migrated to various ferrous and
non-ferrous materials that better support temperature
variations, high unit surface loading, frictional
requirements, and dimensional distortions typical of
today’s advanced engine designs. The constant that
must be maintained to ensure part function of the
sealing system is the specification and consistency of
the surfaces involved. There are very specialized ISO
standard parameters that were designed to describe
plateaued finished surfaces. These are the bearing ratio
parameters (Rpk, Rk, and Rvk) and, more recently, the
probability parameters (Rpq, Rmq, and Rvq). They
monitor the peak and valley regimes of the surface,
independently allowing the production team to know
that the process and, therefore, the piece part, will
function.
Figure 3 – Improved performance and service life can
be developed with high intensity isotropic finishing
methods such as centrifugal barrel finishing. (Photo
credit: D, A, Davidson, SME MMR Tech Community)
Gear contact surfaces: Gears of all types must be
designed to maintain their integrity under very high
local surface loads (see Figure 3). The industry has
always battled what material, what form, what surface
will survive the varying designs and environments.
Again, the surface must distribute the lube well and, at
the same time, have the capability to withstand very
high unit area load. Generally, the plateauing process
will produce a surface free of local anomalies that can
increase the local unit load and initiate a failure site.
The mechanisms for surface failure are many and,
sometimes, are difficult to identify. It has been found
that when attention is paid to the integrity of the
contacting gear surfaces by reporting the correct
parameters during production, gear life is extended,
noise and operating temperatures are reduced, and wear
is minimized.
The Importance of surface finish design for function:
The mechanism that allows for improved
“functionality” for all surfaces is basic to surface
performance —to accept the loads imposed and resist
wear. Traditional processes that generate form and
control fit do not necessarily dictate whether that part or
assembly will function. Over the last three decades, it
has been realized that there is another contributor to part
performance—surface finish. If a manufacturer does not
account for surface finish characteristics like lube
retention, micro burr removal, identification of torn and
folded material, directionality, and load-bearing
capability, the performance of components in the system
cannot be predicted. Through progressive process
development, evolving measures (new ISO standard
parameters), and a mature understanding of the
“function” of surfaces, manufacturers can design parts
that become assemblies that are in systems performing
over predictable, extended lives. This is the key to
reduced warranty costs, reduced scrap, lower production
costs, and satisfied customers.
Case study—Mechanical surface finish method
originally justified for cost and direct labor
reduction produces important performance related
edge/surface effects. Turbo-abrasive machining [TAM]
is an emerging edge and surface finish technology for
processing gas turbine rotating hardware. This method
is used primarily for deburring and edge contour
development on feature edges, especially those located
on the peripheral or circumferential area of turbine and
compressor discs. The process is capable of producing
consistent and uniform edge and surface effects on these
critical areas. Currently, much of this work is performed
manually or with single point-of-contact methodologies
with relatively high reject/rework rates. Although much
of the economic justification for adopting TAM
technologies is centered around the substantial
automation of direct labor and the attendant cost
reductions, an even more important consideration is the
potential for improvements in part performance and
functionality. The process has a number of
characteristics that are potentially important for long-
term service utility of components in operation. Among
these is a process-developed compressive stress
equilibrium—as all edge features are processed
3. 3
identically and simultaneously.
Very sophisticated surfaces are being developed to
improve contact fatigue in gears. Vibratory, centrifugal
and specialized spindle systems are being used to
improve bearing load and fatigue life properties. The
gear shown above was processed in a multi-sequence
centrifugal operation to bring contact surfaces of the
gear below 10 micro-inch Ra.
Figure 4 – Aerospace rotating hardware edge and
surface finished with Turbo-Abrasive Machining (TAM).
(Photo credit: Dr. Michael Massarsky, Turbo-Finish
Corporation)
With TAM (Turbo-Abrasive Machining) processing,
stresses on critical edge areas of features, such as those
found in turbine disc broach slots, (See Figure 4) have a
uniformity not possible to achieve with either manual or
single point-of-contact processing; parts are also
improved by changes developed on the overall surface
of parts. Unlike conventional machining or grinding
methods, TAM procedures develop non-linear
(isotropic) surface patterns that are far less subject to
potential surface crack initiation and propagation and
have the added advantage of promoting surfaces with
higher levels of contact rigidity for seal joint contact
enhancement. Additionally, the procedure changes the
nature of surface skews, traditional or conventional
machined surfaces are characterized by positively
skewed surface profiles in which surface peaks are the
predominant surface feature. This is a surface
characteristic consequence common to most all standard
machining and grinding methods. Abusive machining
and grinding exacerbates this natural, but undesirable,
surface characteristic. In contrast, TAM surfaces are
characterized by negative or neutral skews in which the
surface texture pattern is far more random and multi-
directional than those produced by machine cutting
tools or grinding wheels. This more homogenous
surface pattern has an additional functional advantage in
that load bearing and wear resistance qualities of
surfaces are improved as a direct result. TAM is a
“cool” process that is more nonselective than traditional
processing, and there is little temperature phase shift
involved as the edges and surfaces of parts are altered.
Two basic mechanisms are involved in this machining
process: (See Figure 5)
(1) Envelopment of rotational parts within a fluidized
bed of relatively small abrasive granular media, and
(2) Fixtured parts are rotated at sufficient speed to
develop effective intensity interaction between part
surfaces and edges, and the abrasive particles suspended
and constantly replenished within the fluidized bed area.
Figure 5 – Rotating aerospace hardware can be rapidly
edge and surface finished using a high-speed, dry,
horizontal spindle finishing method known as TAM
(Turbo-Abrasive Machining) Photo credit: Dr. Michael
Massarsky, Turbo-Finish Corporation
Some Case Studies -- Edge and surface finishing for
improved performance and fatigue failure
resistance: The technical literature is replete with
examples of case studies indicating that substantial
fatigue resistance can be developed with mass finishing
methods such as barrel finishing. One study published
by Iron Age magazine back in 1959 documented studies
on the compressive stresses to be developed with
various types of abrasive and non-abrasive media in
tumbling barrels.
Some processes are especially well known for this
characteristic. Steel media or ball burnishing processes
using vibratory techniques are known not only for
producing aesthetically pleasing surfaces, but also
enhancing service life of components because of the
bulk-density of the media itself (300 lb./ft3
as compared
to 80 to 100 lb./cu. Ft3
with typical abrasive ceramic
media types). Some promising research has been done
by major aerospace companies that indicate large air
frame components can be processed to enhance fatigue
4. 4
life, and that fatigue life of components stressed or
weakened in service can be improved during overhaul
cycles as well.
Hignett, in writing a technical paper for SME in
1979, spelled out several applications where high
intensity centrifugal barrel finishing was specified
specifically because of the part performance and service
life attributes the process could develop. Among these
were:
• Components for roller chain and silent chain,
including the slide plates, bushings, rollers and pins.
The centrifugal process was able to deburr, descale,
edge finish, surface finish, and impart compressive
stress on the parts simultaneously. As the loose abrasive
media being used in these systems are applied against
part surfaces with relatively high pressure, very small
media were utilized to completely and uniformly deburr
and radius through holes on the side plates without
rolling the burrs over. Other finishing methods could
not accomplish this, and, as a result, sharp edges would
be exposed when burrs were “torn” off in assembly,
creating a stress raiser that would contribute to
premature failure of chains due to fatigue cracks
initiating at the sharp edge. Like many other similar
applications, the success of this process was dependent
on the process’s ability to produce “holistic” changes in
the parts themselves on a number of different levels.
These changes not only contributed to the dimensional
uniformity of the parts, permitting more automated
assembly, but also changed the nature of part edge and
surface characteristics and stress conditions in a way
that not only facilitated extended service life, but
actually made the service life more predictable.
Figure 6 – Micro-finishes are developed on dental and
medical components with centrifugal isotropic finishing.
(Photo credit: T. Mathisen, Mass Finishing Inc.)
• Dental partials and orthodontic bands, brackets,
and wire parts: In recent years, high-pressure
centrifugal finishing has become a standard method for
producing needed edge and surface finish quality for
these parts, reducing finishing costs by as much as 70%
over manual methods. Given the fact that the end
destination for the parts are inside the end user’s mouth,
uniformly consistent edge contour and very refined low
micro-inch surface finishes without dimensional
distortion are required. Like many demanding surface
condition treatment applications, several different cycles
using successively finer abrasive materials may be
required to achieve the needed result. As can be
imagined, the improved fatigue and wear resistance
properties are product attributes that contribute to
customer satisfaction considerably.
Figure 7 - Edge-finishing with mass finishing methods
can improve speed and feed performance and service
life of cutting tools (Photo credit: D. A. Davidson, SME
MMR Tech Community)
• Carbide and HSS tooling: A number of different
mass finishing operations are utilized by the cutting tool
industry to develop edge and surface finishes on the
tooling that contribute to improved cutting performance
and tool longevity. Vibratory equipment, especially
equipment equipped with high-frequency electro-
magnetic drives, is utilized to produce uniform edge-
hone or edge preparation on carbide inserts to improve
cutting performance and tool life. High-pressure
finishing methods, some of them employing part
fixtures, are also used to produce specialized edge and
surface finish effects on both carbide and HSS tooling.
Among the methods employed are centrifugal barrel
processing and several different variants of “drag
finishing.” Some processes produce edge and surface
effects by pressure and compression, utilizing relatively
high bulk-density non-abrasive loose media in “wet-
processes.” Other, more fixture-centric methods apply
low bulk- density dry media with micro-fine abrasives
5. 5
against tooling edges and surfaces at very high rates of
pressure and flow. Significant improvements in tool
performance and longevity are claimed for both “new”
tools and “resharps” that have edge and surface
conditions modified with these types of methods. Parts
currently being processed include end-mills, drill-bits,
spade blades, broaches, hobs, and even circular saw
blades for power tools. (See Figure 7) Several
manufacturers claim tool life increases of 200 to 300%
for tools processed by these methods, in some cases
obviating the need for coatings.
Figure 8 – Conventional surfaces produced by grinding
and machining exhibit positively skewed non-isotropic
surfaces such as the three views seen in this figure.
(Photo courtesy of Jack Clark, Surface Analytics, LLC)
Figure 9 – This figure shows three views of the same
part with isotropic surfaces with neutral surface profile
skews developed with high-intensity centrifugal
finishing. (Photo courtesy of Jack Clark, Surface
Analytics, LLC)
• Reed and flapper valves: These reed components are
sometimes flexed more than 12,000 cycles per minute in
normal service. Centrifugal barrel finishing promotes
extended fatigue life on these components by
developing both generous edge-contours to limit stress
concentration points, as well as simultaneously
developing low-profile surfaces with high compressive
stress properties. One case study cited a reduction in the
number of fatigue failures developing at the predicted
half-life of the part of over 95% when surface finished
with centrifugal methods.
• Stainless steel coil spring fatigue resistance: An
extensive comparative testing program was conducted
to evaluate high-pressure (centrifugal barrel) methods as
a means to improve fatigue life (see also Figure 8 and 9)
on coil springs. In one test, the coil springs were tested
to failure by depressing them from 1.104-inch lengths to
0.730 inch, developing a stress change from 0 to 50,000
psi. The coil springs processed with conventional
surface finish and shot peening methods all failed
between 160,000 and 360,000 cycles. Parts processed in
a single, high-pressure centrifugal barrel method for 20
minutes failed between 360,000 and 520,000 cycles, a
typical performance increase of 60%. All centrifugally
finished parts that failed below 400,000 cycles did so
because of clearly visible surface defects or inclusions.
These parts could have been easily removed from the
production stream by visual inspection because of the
prominence of the defect, given the refined surface
finish. Such defects were masked because of the highly-
textured nature of the peened surfaces, making visual or
optical elimination near impossible. Tests performed on
another set of production springs were even more
striking, with all springs processed in standard or
conventional processes, failing before 600,000 cycles,
and none of the same springs processed in high-pressure
centrifugal methods failing before the 800,000 cycle
limit of the test.
Figure 10 – Very refined surfaces can be developed on
critical hardware by processing parts in several steps
with successively finer abrasive or polishing materials.
(Photo courtesy of Dr. Michael Massarsky, Turbo-
Finish Corporation)
6. 6
The importance of edge and surface condition
quality: Deburring and surface conditioning has often
been treated as the “poor relation” or “step-child” of
manufacturing engineering. Many parts and components
have been shown to have sub-optimal performance
because of a lack of edge and surface-quality conscious
design. Edge and surface finish can be an important
factor in driving ultimate part performance and
functionality. In what has become a standard reference
on the subject, (“Deburring and Edge Finishing
Handbook”) author LaRoux Gillespie enumerated 25
different potential problem areas that might result from
insufficient care being given to edge and surface
finishing process selection. They are:
• cut hands in assembly or disassembly;
• interference fits (from burrs) in assemblies;
• jammed mechanisms (from burrs);
• scratched or scored mating surfaces (which allow seals
to leak);
• friction increases or changes (disallowed in some
assemblies);
• increased wear on moving or stressed parts;
• electrical short circuits (from loose burrs);
• cut wires from sharp edges and sharp burrs;
• unacceptable high-voltage breakdown of dielectric;
• irregular electrical and magnetic fields (from burrs);
• detuning of microwave systems (from burrs);
• metal contamination in unique aerospace assemblies;
• clogged filters and ports (from loose burr
accumulation);
• cut rubber seals and O-rings;
• excessive stress concentrations;
• plating buildup at edges;
• paint buildup at edges (from electrostatic spray over
burrs);
• paint thin out over sharp edges (from liquid paints);
• edge craters, fractures, or crumbling (from initially
irregular edges);
• turbulence and non-laminar flow;
• reduced sheet metal formability;
• inaccurate dimensional measurements;
• microwave heating at edges;
• reduced fatigue limits;
• reduced volumetric efficiency of air compressors;
• reduced cleaning ability in clean room applications;
• reduced photoresist adherence at edges;
• and to the list we would add less aesthetic appeal.
To summarize, are we certain that we clearly understand
how edge and surface finish quality might contribute to
how manufactured parts and components will function,
perform and last in service? Tools are readily available.
Will we use them? To an increasing degree, to borrow a
well-worn phrase used by one finishing compound
manufacturer, “It is the finish that counts.” □
Further reading: Internet resources
(1) “Isotropic Mass Finishing for Surface Integrity and Part
Performance”, Article From: Products Finishing, Jack Clark,
from Surface Analytics, LLC and David Davidson, from SME
Deburr/Finish Technical Group, Posted on: 1/1/2015, [Barrel,
vibratory, centrifugal and spindle finish can improve part
performance and service life.]
http://www.pfonline.com/articles/isotropic-mass-finishing-for-
surface-integrity-and-part-performance
(2) “Turbo-Charged Abrasive Machining Offers Uniformity,
Consistency” Article From: Products Finishing, by: Dr.
Michael Massarsky, President from Turbo-Finish Corporation,
and David A. Davidson, from SME Deburr/Finish Technical
Group. Posted on: 6/1/2012. [Method can deburr, produce
edge contour effects rapidly]
http://www.pfonline.com/articles/turbo-charged-abrasive-
machining-offers-uniformity-consistency
(3) “Turbo-Abrasive Machining and Finishing”.
MANUFACTURING ENGINEERING – Aerospace
Supplement, by: Dr. Michael Massarsky, President from
Turbo-Finish Corporation, and David A. Davidson, from SME
Deburr/Finish Technical Group. [Method first developed for
the aerospace industry can improve surface integrity and part
performance]
http://www.slideshare.net/dryfinish/turboabrasive-machining-
me-aerospace-supplement-reprint
(4) “The Role of Surface Finish in Improving Part
Performnce”, MANUFACTURING ENGINEERING, by Jack
Clark, Surface Analytics.com and David A. Davidson, from
SME Deburr/Finish Technical Group.
http://www.slideshare.net/dryfinish/november-2012-f4-
deburring-1-final
(5) “Free Abrasives Flow for Automated Finishing”,
MANUFACTURING ENGINEERING, , by: Dr. Michael
Massarsky, President from Turbo-Finish Corporation, and
David A. Davidson, from SME Deburr/Finish Technical
Group. [Exciting new methods of surface finishing that go
beyond deburring to specific isotropic surface finishes that can
increase service life]
http://www.slideshare.net/dryfinish/october-2013-f2-
deburring-1
(6) Turbo-Abrasive Machining Demonstration Video:
https://www.youtube.com/watch?v=jYxqCxMIHNo
(7) SME Spokane, WA Factory Floor video, Centrifugal
Finishing in the Precision Machine Shop: Demonstration)
https://www.youtube.com/watch?v=dUdKjaysTYM