advanced manufacturing technology research laboratory (amtrel) liverpool john moores university...
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Advanced Manufacturing Technology Research Laboratory (AMTReL)Liverpool John Moores University
SUMMARY OF RESEARCH RESULTS
April, 2012Prepared by: Mr. Pitipong BenjarungrojSupervised by: Dr. Michael M Morgan
INVESTIGATION OF THERMALLY TREATED RECYLED GLASS AS A VIBRATORY MASS FINISHING MEDIA:
Performance and Characterisation
Sponsored by: Vibraglaz (UK) Ltd
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Content
Introduction Aims / Objectives Problem Outline Experimental programme Results
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Introduction
Mass finishing refers to the process technologies for generating edge and surface finishes on a wide range of metallic and non-metallic materials
Common edge and surface finish requirements include: deburring,
descaling, surface smoothing, edge-break, radius formation, removal of surface contaminants from heat treatment and other processes, bright finishing, pre-plate or coating surface preparation.
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Introduction: Mass finishing process
Energy is imparted to the abrasive media mass via a vibratory or rotary means to impart motion to it and to cause it to act on the surfaces. [process control parameters: vibration amplitude, frequency, (rotational speed)]
Common mass finishing processes include: vibratory bowl and linear; barrel, centrifugal barrel and centrifugal disk, and rotating barrel
Fluid (compound solutions) required for lubrication (-lower frictional forces and reduce wear), aid swarf removal, cleaning, ease handling
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Introduction: Mass finishing process
Centrifugal barrel
Vibratory Bowl Linear Vibratory
Centrifugal disk
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Introduction: Mass finishing media
“Media” refers to the abrasive consumable elements used in mass finishing process.
The common media types include natural abrasives, synthetic random media, preformed ceramic and resin-bonded media, and metallic media.
The composition of a media determines whether it is a cutting or finishing type of media.
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Introduction: Mass finishing media
Geometry largely depends on application
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Introduction: Mass finishing media
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Vibratory Finishing
Thermally Treated Recycled Glass Media
:A Report on outcomes of the first research with this innovative product
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Introduction
The media under investigation is produced wholly from recycled glass. In its raw state it is in cullet form. The cullet is cleaned of contaminants and crushed. The cullet is then sieved and subsequently graded in a manner similar to that for abrasive grains. The source of glass is varied but is in general glass scheduled for landfill and most recently is predominantly window glass.
:presently there is very little knowledge of the performance, capability or mechanical characteristics of this media
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Introduction
Production control requirements:
- mould technology (and release agents)
- heating rate, critical temperature (Tmax), duration at Tmax, cooling rate / quenching
Each have a strong effect on media quality Secret recipe!
This understanding was not available prior to this research
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Introduction
Sample V-Cut media
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New Media Benefits6 key features that distinguish it from other media: No binder required Significantly higher percentage of abrasive Density: plastic media < V-Cut < ceramic media Strong green credentials and low environmental impact Recyclable Lower cost
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Aim / Objectives
To acquire fundamental understanding of the material characteristics of the new development thermally treated recycled media
To obtain machining data over a range of machining conditions
Establish and compare performance of thermally treated recycled media with conventional media
Help develop new products for industrial usage
Help direct the company in identifying the right media for a given job
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Replication methods for surface topography assessment
-identification of cutting edge density
-insight into wear mechanism
Cannot use stylus methods –stylus wear and lack of information on surface features
Materials characterisation
This understanding was not available prior to this research
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Replication Jig and housing Microset 101 RTH Gun and Cartridge
Thru section of replica Jig to lay flat the replica for measurement
Cutting edge density: Replication Technique
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CUTTING EDGE DENSITY - MEASUREMENT
Uniscan Optical interferometer
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Cutting Edge density
Date: 08.06.11Code: A1name: Original - 0 deg
Ra: 120.72 umRz: 1.66 umRq: 167.55 umRt: 1.95 mm
Mesh: 12x12 (144)Sampling: 11.74 umSurface Area: 6 x 6
Total Cutting Edge: 27%cutting edge: 18.75%
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(Larger scale view) Typical surface topography result showing Number of peaks at highest level of the surface
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Cutting Edge Density Measurement
Cutting edge measurement data for thermally treated glass media
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Bearing Ratio ObservationTypical surface topography results
Bearing ratio results
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Ceramic Glass Abrasive Media - Original Fixture 0deg Fixture 90deg
Ceramic Glass vs Strainless Steel at 60 min
Ceramic Abrasive vs Strainless above 60 min
Ceramic Glass Abrasive Media - Original Fixture 0deg Fixture 90deg
Ceramic Glass vs Strainless Steel at 60 min
Ceramic Abrasive vs Strainless above 60 min
Typical surface topography results Bearing ratio results
Bearing Ratio Observation
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Media Comparision
Ceramic
Plastic
V-Cut
60x magnification (CAMApp - desktop equipment)
Note Cutting edge density
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SEM of Thermally Treated Glass
SEM at 100x magnitude SEM at 1000x magnitude
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Performance Assessment
Media Wear rate
Surface roughness , Ra (principal parameter measured)
Brightness observation and Visual inspection (Burr removal)
Cycle times
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Performance Assessment
V-Cut media used in studies
Mass Finisher (vibratory tumbler)
used in studies
Mitutoyo--Series 178 SJ 400 Surftests
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Surface Roughness
Discussion
media 780 is medium grade cutter / polisher
Results are consistent with published data for conventional media(in-house comparative data being prepared)
Limiting values indicate boundary of performance on particular material
For example: If lower Ra is required with material = aluminium, then different grade (i.e. polisher) would be needed, though this would be achieved at the cost of lower material removal rate
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Surface Roughness
Discussion
media 790 performs more as a polisher than media 780
The abrasive action of the media is evident in the early part of the graph – i.e. the cutting edges initially dig into and hence roughen the surfacebefore finishing occurs
This is not so evident with a harder material eg. MS or SS
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Comparison study of thermally treated media and conventional media against industrial components
Roughness observation of conventional media and thermally treated media on benchmark materials
Titanium alloy coupon
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Brightness observation and Visual inspection
Brass before and after 10 minute of machining using Vibraglaz 790
Brass before machining
Brass after machining
using Vibraglaz 780
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Stainless (Virgin)
Mild Steel (machining time 15 minutes)From left to rightMild steel before machiningMild steel machining with Plastic mediaMild steel machining with Vibraglaz 790
Brightness observation and Visual inspection
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Aluminium (machining time 15 minutes)From left to rightAluminium before machiningAluminium machining with Plastic mediaAluminium machining with Vibraglaz 790Aluminium machining with Ceramic media
Brass (machining time 15 minutes)From left to rightBrass before machiningBrass machining with Vibraglaz 770
Brightness observation and Visual inspection
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Brightness observation and Visual inspection
Crank shaft before machining
Crank shaft after machining
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THANK YOU FOR YOUR KIND ATTENTION