Design for Manufacturing Guidebook, Issue II Casting Design GuidelinesDFMPro
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Though there are many kinds of casting processes with distinct design and manufacturing guidelines, we will initially look at the ones which are common to most casting processes. The rules covered in this issue are Fillet Radius, Uniform Wall Thickness, Mold Wall Thickness, Wall Thickness Variations, Undercuts and Draft Angle. Following these guidelines ensures that cast part is manufactured with desired dimensional accuracy, surface finish and quality.
To subscribe to Guidebook, please visit: http://dfmpro.geometricglobal.com/dfm-guidebook/
Design for Manufacturing Guidebook, Issue II Casting Design GuidelinesDFMPro
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Though there are many kinds of casting processes with distinct design and manufacturing guidelines, we will initially look at the ones which are common to most casting processes. The rules covered in this issue are Fillet Radius, Uniform Wall Thickness, Mold Wall Thickness, Wall Thickness Variations, Undercuts and Draft Angle. Following these guidelines ensures that cast part is manufactured with desired dimensional accuracy, surface finish and quality.
To subscribe to Guidebook, please visit: http://dfmpro.geometricglobal.com/dfm-guidebook/
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 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
Turbo abrasive machining tech paper - 2016Dave Davidson
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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.
It's the Finish that Counts. Technical Magazine article reprint.Dave Davidson
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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
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
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 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
Turbo abrasive machining tech paper - 2016Dave Davidson
Â
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.
It's the Finish that Counts. Technical Magazine article reprint.Dave Davidson
Â
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
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
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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.
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
Centrifugal Iso-finishing for Additive Manufactured PartsDDaveDavidson
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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
Centrifugal Iso-Finishing for Additive Manufactured PartsDave Davidson
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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
CAD CAM in dentistry / international orthodontics training centerIndian dental academy
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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.Â
Centrifugal iso finishing for High-Performance SurfacesDave Davidson
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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
Improving profitability for small businessBen Wann
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In this comprehensive presentation, we will explore strategies and practical tips for enhancing profitability in small businesses. Tailored to meet the unique challenges faced by small enterprises, this session covers various aspects that directly impact the bottom line. Attendees will learn how to optimize operational efficiency, manage expenses, and increase revenue through innovative marketing and customer engagement techniques.
LA HUG - Video Testimonials with Chynna Morgan - June 2024Lital Barkan
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Have you ever heard that user-generated content or video testimonials can take your brand to the next level? We will explore how you can effectively use video testimonials to leverage and boost your sales, content strategy, and increase your CRM data.🤯
We will dig deeper into:
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Stay ahead of the curve with our premium MEAN Stack Development Solutions. Our expert developers utilize MongoDB, Express.js, AngularJS, and Node.js to create modern and responsive web applications. Trust us for cutting-edge solutions that drive your business growth and success.
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[Note: This is a partial preview. To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
Sustainability has become an increasingly critical topic as the world recognizes the need to protect our planet and its resources for future generations. Sustainability means meeting our current needs without compromising the ability of future generations to meet theirs. It involves long-term planning and consideration of the consequences of our actions. The goal is to create strategies that ensure the long-term viability of People, Planet, and Profit.
Leading companies such as Nike, Toyota, and Siemens are prioritizing sustainable innovation in their business models, setting an example for others to follow. In this Sustainability training presentation, you will learn key concepts, principles, and practices of sustainability applicable across industries. This training aims to create awareness and educate employees, senior executives, consultants, and other key stakeholders, including investors, policymakers, and supply chain partners, on the importance and implementation of sustainability.
LEARNING OBJECTIVES
1. Develop a comprehensive understanding of the fundamental principles and concepts that form the foundation of sustainability within corporate environments.
2. Explore the sustainability implementation model, focusing on effective measures and reporting strategies to track and communicate sustainability efforts.
3. Identify and define best practices and critical success factors essential for achieving sustainability goals within organizations.
CONTENTS
1. Introduction and Key Concepts of Sustainability
2. Principles and Practices of Sustainability
3. Measures and Reporting in Sustainability
4. Sustainability Implementation & Best Practices
To download the complete presentation, visit: https://www.oeconsulting.com.sg/training-presentations
Tata Group Dials Taiwan for Its Chipmaking Ambition in Gujarat’s DholeraAvirahi City Dholera
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The Tata Group, a titan of Indian industry, is making waves with its advanced talks with Taiwanese chipmakers Powerchip Semiconductor Manufacturing Corporation (PSMC) and UMC Group. The goal? Establishing a cutting-edge semiconductor fabrication unit (fab) in Dholera, Gujarat. This isn’t just any project; it’s a potential game changer for India’s chipmaking aspirations and a boon for investors seeking promising residential projects in dholera sir.
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Vat Registration is a legal obligation for businesses meeting the threshold requirement, helping companies avoid fines and ramifications. Contact now!
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The world of search engine optimization (SEO) is buzzing with discussions after Google confirmed that around 2,500 leaked internal documents related to its Search feature are indeed authentic. The revelation has sparked significant concerns within the SEO community. The leaked documents were initially reported by SEO experts Rand Fishkin and Mike King, igniting widespread analysis and discourse. For More Info:- https://news.arihantwebtech.com/search-disrupted-googles-leaked-documents-rock-the-seo-world/
RMD24 | Debunking the non-endemic revenue myth Marvin Vacquier Droop | First ...BBPMedia1
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Marvin neemt je in deze presentatie mee in de voordelen van non-endemic advertising op retail media netwerken. Hij brengt ook de uitdagingen in beeld die de markt op dit moment heeft op het gebied van retail media voor niet-leveranciers.
Retail media wordt gezien als het nieuwe advertising-medium en ook mediabureaus richten massaal retail media-afdelingen op. Merken die niet in de betreffende winkel liggen staan ook nog niet in de rij om op de retail media netwerken te adverteren. Marvin belicht de uitdagingen die er zijn om echt aansluiting te vinden op die markt van non-endemic advertising.
What are the main advantages of using HR recruiter services.pdfHumanResourceDimensi1
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3.0 Project 2_ Developing My Brand Identity Kit.pptxtanyjahb
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A personal brand exploration presentation summarizes an individual's unique qualities and goals, covering strengths, values, passions, and target audience. It helps individuals understand what makes them stand out, their desired image, and how they aim to achieve it.
Personal Brand Statement:
As an Army veteran dedicated to lifelong learning, I bring a disciplined, strategic mindset to my pursuits. I am constantly expanding my knowledge to innovate and lead effectively. My journey is driven by a commitment to excellence, and to make a meaningful impact in the world.
1. Isotropic Mass Finishing for Surface
Integrity and Part Performance
Authors are members of the SME-DESC Technical Group:
David A. Davidson, Deburring/Surface Finish Specialist;
Jack Clark, Applications Engineering Manager, ZYGO Corporation;
Dr. Michael L. Massarsky, President, Turbo-Finish Corporation
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 hard-
ware 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 insuffi-
cient planning and a lack of understanding on what will be
required to render the manufactured part or component Figure 1. (Before) This photograph was taken with an electron micro-
acceptable for consumer use or end-user application. At the scope at 500x magnification. It shows the surface of a raw unfinished
root of the problem is a manufacturing and design engineer- “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
ing culture that considers its work done when the part comes most cast, ground, turned, milled, EDM and forged surfaces, this
off the machining center or the fabricating machine. Too surface shows a positive Rsk [Rsk – skewness – the measure of surface
often, part edge and surface condition is simply someone symmetry about the mean line of a profilometer graph. Unfinished
else’s problem. In many cases not much thought is given to parts usually display a heavy concentration of surface peaks above
this mean line, generally considered to be an undesirable surface finish
the problem until production is in full swing and parts start to characteristic from a functional viewpoint.]
fail quality assurance standards because they have burrs or
undesirable surface conditions that not only affect function
and performance but send costs through the roof.
This is a situation that deserves and is getting an increas-
ing amount of scrutiny. It is a subject repeatedly discussed at
the newly-formed “Deburring, Edge-Finish, and Surface
Conditioning Technical Group” sponsored by the Society of
Manufacturing Engineers in Dearborn, Michgan. At one of the
group’s monthly national teleconferences, Steven Alviti, a
deburring and surface finish expert, summarized his experience
this way:
“This group has been needed for a long time now. The senti-
ments expressed at the phone conference still hold true to
this day. I face the same scenario time after time. The company Figure 2. (After) This SEM photomicrograph (500X magnification) was
develops a new product, they cost the product, they work taken after processing the same turbine blade in a multi-step procedure
out the productivity to decide what machinery they need to utilizing centrifugal barrel methods with both grinding and polishing
free abrasive materials in sequence. The surface profile has been
supply the demand, they spend $500,000.00 - $1,000,000.00 reduced from the original 75 – 90 Ra (µin.) to a 5-9 Ra (µin.) range.
for CNC machinery, they get orders and start producing, Additionally, there has been a plateauing of the surface and the
they now have product to ship -- but it has a burr! Now we resultant smoother surface manifests a negative skew (Rsk) instead of a
get the call, after they have thrown five or six people at the positive skew. This type of surface is considered to be very “functional”
in both the fluid and aerodynamic sense. The smooth, less turbulent
cell with microscopes, exact-o-knifes, files, sandpaper and flow created by this type of surface is preferred in many aerodynamic,
worse, and have figured out that they are in a jam. Now we automotive and other high force loading applications. Another
come up with a mechanical or automated solution, but it's important consideration the photomicrographs indicate is that surface
like pulling teeth to have them spend $10,000 or $20,000 and sub-surface fractures seem to have been removed. Observations
with backscatter emission with a scanning electron microscope (SEM)
on a solution that should have been part of the initial phase. gave no indication of residual fractures.
Whatever this group can do to bring mass finishing into the
initial stages of engineering will be a benefit to all involved.” budgetary, capital asset acquisition and purchasing processes
The costs of neglecting to consider deburring and surface for something as mundane as deburring and surface finishing
conditioning in production planning and engineering can be equipment. The reason this problem persists into the 21st
– and often is – substantial. Frequently overlooked however, century is that there is a very imperfect understanding of the
are the potentially serious problems that can develop from the hidden and more serious cost this manual and uncontrolled
ad hoc and interim solutions that are selected to deal with approach imposes.
what now has become a manufacturing crisis. The manufac- The first casualty of this manual approach is the invest-
turers who resort to hand or manual finishing do not do so ment the manufacturer has made, often in the millions, for
because of its cost. On a per piece basis, it is by far the most precise and computer controlled manufacturing equipment.
costly method of handling the problem – but often it is the The idea behind this investment was to have the ability to
most obvious solution and the easiest and the quickest to produce parts that are uniformly and carefully manufactured to
implement. Hiring some less-skilled temporary employees, and exacting specifications and tolerances. At this point, in too
arming them with hand tools to attack the problem, may not many cases, the parts are then handed off to manual debur-
be very imaginative, but it is certainly much less strenuous ring and finishing procedures that will guarantee that no two
from an engineering perspective than approaching the parts will ever be alike.
Continued on page 8
Fall 2006 6 The Shot Peener
2. ISOTROPIC MASS FINISHING
Continued from page 6
Moreover, the increased complexity and precision require-
ments of mechanical products have reinforced the need for
accurately producing and controlling the surface finish of
manufactured parts. Variations in the surface texture can
influence a variety of performance characteristics. The surface
finish can affect the ability of the part to resist wear and
fatigue, to assist or destroy effective lubrication, to increase
or decrease friction and/or abrasion with cooperating parts,
and to resist corrosion. As these characteristics become critical
under certain operating conditions, the surface finish can
dictate the performance, integrity and service life of the
component.
The role of mass finishing processes (barrel, vibratory and Figure 4. Edge and surface condition can produce dramatic improvements
centrifugal finishing) as a method for removal of burrs, devel- in performance and service life as this comparison between manually
oping edge contour and smoothing and polishing parts, has deburred and mechanically edge-contoured parts demonstrates.
been well established and documented for many years. These The Turbo-Finish method also develops compressive stress and stress
processes have been used in a wide variety of part applications equilibrium in large critical rotating components. Courtesy of
Turbo-Finish Corporation
to promote safer part handling (by attenuation of sharp part
edges) improve the fit and function of parts when assembled, Positive vs. Negative Surface Skewness. The skew of surface
and produce smooth, even micro-finished surfaces to meet profile symmetry can be an important surface attribute. Surfaces
either functional or aesthetic criteria or specifications. Processes are typically characterized as being either negatively or
for developing specific edge and/or surface profile conditions positively skewed.
on parts in bulk are used in industries as diverse as the jewelry, This surface characteristic is referred to as Rsk (Rsk – skew-
dental and medical implant industries on up through the ness – the measure of surface symmetry about the mean line
automotive and aerospace industries. Less well known and of a profilometer graph). Unfinished parts usually display a
less clearly understood is the role specialized variants of these heavy concentration of surface peaks above this mean line (a
types of processes can play in extending the service life and positive skew). It is axiomatic that almost all surfaces produced
performance of critical support components or tools in by common machining and fabrication methods are positively
demanding manufacturing or operational applications. skewed. These positively skewed surfaces have an undesirable
Industry has always been looking to improve surface effect on the bearing ratio of surfaces, negatively impacting
condition to enhance part performance, and this technology the performance of parts involved in applications where there
has become much better understood in recent years. is substantial surface-to-surface contact. Specialized high energy
Processes are routinely utilized to specifically improve life of finishing procedures can truncate these surface profile peaks
parts and tools subject to failure from fatigue and to improve and achieve negatively skewed surfaces that are plateaued,
their performance. These improvements are mainly achieved presenting a much higher surface bearing contact area.
by enhancing part surface texture in a number of different, Anecdotal evidence confirms that surface finishing procedures
and sometimes complimentary, ways. tailored to develop specific surface conditions with this in
To understand how micro-surface topography improvement mind can have a dramatic impact on part life. In one example
can impact part performance, some understanding is required the life of tooling used in aluminum can stamping operations
of how part surfaces developed from common machining, was extended 1000% or more by improved surface textures
grinding and other methods can negatively influence part produced by mechanical surface treatment.
function over time. The following factors are involved.
Directionalized vs. Random (Isotropic) Surface Texture
Patterns. Somewhat related to surface texture skewness in
importance is the directional nature of surface textures devel-
oped by typical machining and grinding methods. These
machined surfaces are characterized by tool marks or grinding
patterns that are aligned and directional in nature. It has been
established that tool or part life and performance can be sub-
stantially enhanced if these types of surface textures can be
altered into one that is more random in nature. Post-machin-
ing processes that utilize free or loose abrasive materials in a
high energy context can alter the machined surface texture
substantially, not only reducing surface peaks, but generating
a surface in which the positioning of the peaks has been
altered appreciably. These “isotropic” surface effects have been
demonstrated to improve part wear and fracture resistance,
bearing ratio and improve fatigue resistance.
Residual Tensile Stress vs. Residual Compressive Stress.
Many machining and grinding processes tend to develop
residual tensile stresses in the surface area of parts. These
residual tensile stresses make parts susceptible to premature
Figure 3. These profilometer graphs graphically illustrate in 2-D the fracture and failure when repeatedly stressed. Certain high-
difference between an as-cast positively skewed surface, and the same
typical surface processed with a sequence of high energy loose media energy mass finishing processes can be implemented to modify
operations to produce an improved surface topology that that is potentially this surface stress condition, and replace it with uniform resid-
very useful for mission critical components that require improved wear, ual compressive stresses. Many manufacturers have discovered
fracture or fatigue resistance. that as mass finishing processes Continued on page 10
Fall 2006 8 The Shot Peener
3. ISOTROPIC MASS FINISHING These alterations in surface characteristics often improve part
Continued from page 8 performance, service life and functionality in ways not clearly
understood when the processes were adopted. In many appli-
have been adopted, put into service, and the parts involved cations, the uniformity and equilibrium of the edge and sur-
have developed a working track record, an unanticipated face effects obtained have produced quality and performance
development has taken place. Their parts are better—and not advantages for critical parts that can far outweigh the sub-
just in the sense that they no longer have burrs, sharp edges stantial cost-reduction benefits that were the driving force
or that they have smoother surfaces. Depending on the behind the initial process implementation.
application, they last longer in service, are less prone to metal This assertion has been affirmed by both practical produc-
fatigue failure, exhibit better tribological properties (translation: tion experience and validation by experiment in laboratory
less friction and better wear resistance) and from a quality assur- settings. David Gane and his colleagues at Boeing have been
ance perspective, are much more predictably consistent and studying the effects of using a combination of fixtured-part
uniform. The question that comes up is why do commonly vibratory deburring and vibratory burnishing (referred to by
used mass media finishing techniques produce this effect? them as “Vibro-peening” or “Vibro-strengthening”) processes
There are several reasons. The methods typically are non- to produce (1) sophisticated edge and surface finish values
selective in nature. Edge and surface features of the part are and (2) beneficial compressive stress to enhance metal fatigue
processed identically and simultaneously. Additionally, they resistance. In life cycle fatigue testing on titanium test coupons,
consistently develop beneficial compressive stress equilibriums. it was determined that the vibro-deburring/burnishing
Continued on page 12
Figure 5. Centrifugal barrel
machines such as these can pro-
duce exceptional edge and surface
finishes in very short cycle times.
Accelerated process effects can be
developed because of the high
speed interaction between abrasive
media and part surfaces, and
because media interaction with
parts are characterized by high
pressure by virtue of the high cen-
trifugal forces developed in the processes. Smaller turbine blades can be
processed in the 5 x 8 inch compartments in the 12-liter capacity machine
shown to the right. Larger centrifugal machines such as the 220 liter or
330 liter capacity machine shown to the left can handle much larger parts
as the barrel compartments are as much as 42 inches in length. Larger
parts processed in this type of machinery can be processed one at a time
within the barrel compartment suspended within the media mass or be
fixtured. Barrel compartments can be divided into processing segments to
accommodate more than one part.
Figure 6. Increasingly sophisticated measurement methods are now utilized
to characterize surface textures so that a more accurate correlation Figure 7. The 3-D color characterization shown in the earlier graphic
between surface texture and its possible effect on ultimate part perform- in this series is based on a surface characterization of the “AS
ance and longevity can be drawn. Especially useful is the 3-D surface tex- GROUND” photo and microphotograph shown here. The graphics in
ture characterization, such as the one shown in the upper right hand this set have been arranged for ease of comparison in terms of differen-
graphic of this grouping. Optical interferometry and computer enhanced tiating surface characteristics produced by various manufacturing
graphics make it possible to visualize potentially detrimental surface char- methods. The lower left item of each set illustrates the type of surface
acteristics in ways not previously possible. The graphics shown are surface developed from mass finishing methods (in this case centrifugal barrel
characterizations of a finely ground roller bearing. As the 3-D graphic finishing [CBF]) contrasted with grinding or machining methods.
clearly shows this is a dysfunctional surface, from both a wear resistance Clearly evident in the SEM (scanning electron microscope) micropho-
and a metal fatigue resistance perspective. In this case, both the predomi- tographs is the fact the centrifugal barrel process has been able to
nant surface peaks and lack of isotropicity (random surface texture pattern) create a surface that has been plateaued (surface peaks and asperities
are going to contribute to premature part failure and suboptimal perform- have been leveled for much higher bearing load capabilities and
ance. It should be understood that these types of surface characteristics are reduced crack propagation) and is isotropic in nature (a non-directional
not necessarily the result of mistakes or errors, almost all common types of surface pattern). These desirable surface characteristics have been
machining, grinding or fabrication methods produce surface characteris- developed concurrently with a highly advantageous stress equilibrium
tics of this nature. When correctly implemented, mass finishing processes effect in a single process. Photos courtesy of Jack Clark, Zygo
are capable of correcting these inherent surface flaws by developing Corporation.
plateaued isotropic surfaces while simultaneously developing beneficial
compressive stress and a stress equilibrium to the entire part. Graphic
courtesy of Jack Clark, Zygo Corporation.
Fall 2006 10 The Shot Peener
4. ISOTROPIC MASS FINISHING [Consortium on Deburring and Edge Finishing], University of California at
Continued from page 10 Berkeley, June 2004
Massarsky, M. L., Davidson, D. A.., “Turbo-Abrasive Machining - A New
method produced metal fatigue resistance that was compara- Technology for Metal and Non-Metal Part Finishing”, THE FINISHING LINE, Vol.
ble to high intensity peening that measured 17A with Almen 18 No. 4, Dearborn MI: Association of Finishing Processes, Society of
Manufacturing Engineers, Oct. 30, 2002
strip measurements. The striking difference between the two
methods however, is that the vibratory burnishing method Massarsky, M. L., Davidson, D. A., “Turbo-Abrasive Machining and Turbo-
Polishing in the Continuous Flow Manufacturing Environment”, SME Technical
produced the effect while retaining an overall surface rough- Paper MR99-264, CONFERENCE PROCEEDINGS: 3rd International Machining
ness average of 1 ĂŚm (Ra), while surface finish values on the and Grinding Conference, Cincinnati, OH, Oct 4-7, 1999, Dearborn, MI:
test coupon that had been processed with the 17A high Society of Manufacturing Engineers, 1999
intensity peening had climbed to values between 5-7 ĂŚm (Ra). Gillespie, LaRoux, Deburring and Edge Finishing Handbook, Dearborn, MI:
The conclusion the authors reached in the study was that the Society of Manufacturing Engineers, 1999
practicality and economic feasibility of the vibro-deburring and Davidson, D. A., “Mass Finishing Processes”, 2002 METAL FINISHIING GUIDE
burnishing method increased with part size and complexity. BOOK AND DIRECTORY, White Plains, NY: Elsevier Science, 2002
Dr. Michael Massarsky of the Turbo-Finish Corporation
was able to supply comparative measurements on parts
processed by his method for edge and surface finish improve-
ment. Utilizing this spindle oriented deburr and finish method
it is possible to produce compressive stresses in the MPa = 300
- 600 range that formed to a surface layer of metal to a depth
of 20 - 40 µm. Spin pit tests on turbine disk components
processed with the method showed an improved cycle life of
13090 ± 450 cycles when compared to the test results for
conventionally hand deburred disks of 5685 ± 335 cycles, a
potential service life increase of 2 – 2.25 times, while reducing
the dispersion range of cycles at which actual failure
occurred. Vibratory tests on steel test coupons were also
performed to determine improvements in metal fatigue resist-
ance. The plate specimens were tested with vibratory ampli-
tude of 0.52 mm, and load stress of 90 MPa. The destruction
Figure 8. This large power generation turbine blade was made utilizing
of specimens that had surface finishes developed by the 6-axis machining technology. Centrifugal barrel finishing technology was
Turbo-Finish method took place after: used to clear and blend in the milling cutter paths and then develop very
(3 - 3.75)*104 cycles refined and burnished isotropic surfaces in the foil area.
a significant improvement over tests performed on conven-
tionally ground plates that started to fail after:
(1.1 - 1.5)*104 cycles.
SUMMARY:
Mass media finishing techniques (barrel, vibratory, centrifugal
and spindle finish) can be used to improve part performance
and service life, and these processes can be tailored or modi-
fied 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 perform-
ance and service life are not. This facet of edge and surface
Figure 9. This large aircraft engine turbine disk has been processed with
finish processing needs to be better understood and deserves the Turbo-Finish method. This dry abrasive finishing method has been
closer study and documentation. Industry and public needs successful in bringing mass media finish economies to large complex
would be well served by consortium of partners at the industry, rotationally oriented parts while simultaneously developing significant
university and governmental agency levels capable of compressive stress. In addition to the uniform and consistent edge contours
developed, the method also produces highly sophisticated isotropic surface
researching all aspects of surface texture and surface condi- finishes by radically altering the character of the as- machined or
tioning related to part functionality, performance and service as-ground surface finish. PHOTO courtesy Dr. Michael L. Massarsky,
life. At the time of this writing, possible FAA intervention bring- Turbo-Finish Corporation
ing the use of manual deburring techniques on commercial
aircraft engine components under closer control are apparently
being considered.
ACKNOWLEDGEMENTS: The author wishes to acknowledge the
technical assistance of the following members of the Society of
Manufacturing Engineer’s DESC Technical Group [Deburring, Edge-
Finish, Surface Conditioning]. Dr. Michael Massarsky, Turbo-Finish
Corporation; David H. Gane, Boeing; Edward F Rossman Ph. D.,
.
Boeing; Jack Clark, ZYGO Corporation; LaRoux Gillespie, PE, CMfgE,
Honeywell. Rodney Grover, Society of Manufacturing Engineers.
REFERENCES:
(1) Gane, David H., Rumyantsev, H.T., Diep, Bakow, L."Evaluation of
Vibrostrengthening for Fatigue Enhancement of Titanium Structural Figure 10. These titanium test coupons show a before and after example of
Components on Commercial Aircraft". Ti-2003 Science and Technology; mass finishing processes being used to blend in milling cutter paths.
Proceedings of the 10th World Conference on Titanium, Hamburg Germany, Transforming the positively skewed surface profiles of machined parts into
13-18 July 2003, Edited by G. Lutejering and J Albrecht.WILEY-VCH Vol 2. parts with isotropic and negatively skewed surface characteristics can be
pp 1053-1058 an important element in any program where surface improvements are
Massarsky, M. L., Davidson, D. A., “Turbo-Abrasive Machining, CODEF being developed to improve wear resistance and metal fatigue resistance
PROCEEDINGS, 7th International Deburring Conference, Berkeley, CA.: CODEF on critical parts.
Fall 2006 12 The Shot Peener