turbo abrasive finishing
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Lean Deburringwith Turbo-Abrasive
Finishing
Lean Deburringwith Turbo-Abrasive
Finishing
SOCIETY OF MANUFACTURING ENGINEERSby Michael Massarsky Ph.D; President
Turbo-Finish [email protected]
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Basic Turbo-Finish PrinciplesBasic Turbo-Finish Principles
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Spindle run time effects contour developmentSpindle run time effects contour development
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Edge contour – simultaneous and identical produces stress equilibrium…Edge contour – simultaneous and identical produces stress equilibrium…
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Disk feature improvement Disk feature improvement
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Before and After example – Turbo-Finish produces isotropic surface finishBefore and After example – Turbo-Finish produces isotropic surface finish
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BEFORE and AFTER – Burr Removal and Isotropic surface generationBEFORE and AFTER – Burr Removal and Isotropic surface generation
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BEFORE and AFTER -- Burr Removal and edge contour generation.
BEFORE and AFTER -- Burr Removal and edge contour generation.
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Burr Removal from Drilled Burr Removal from Drilled
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Turbo-Finish Radius Generation ChartTurbo-Finish Radius Generation Chart
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Radius development on dove tail slotsRadius development on dove tail slots
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Edge contour development on rotor styled partsEdge contour development on rotor styled parts
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Planetary fixturing for turbine blade finishingPlanetary fixturing for turbine blade finishing
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Disk slot features before Turbo-Abrasive MachiningDisk slot features before Turbo-Abrasive Machining
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Edge finish after processingEdge finish after processing
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Profilometer readings showing surface profile reduction.Profilometer readings showing surface profile reduction.
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LEAN Rapid Edge Contour – Isotropic Finish of Large Rotational Aerospace Components with TAM
Turbo Abrasive Machining technology replaces batch and queue hand deburr with LEAN cellular machining concept.
Drives down defect rate to near zero. Drives down WIP from hours to minutes in single piece continuous flow
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Turbo Abrasive Machining – Lean DeburringTurbo Abrasive Machining – Lean Deburring
This machine was built to deburr and edge-contour turbine and compressor disks up to 20 inches in diameter [500mm]
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Turbo Abrasive Machining Basics Lean Deburring, Lean FinishingTurbo Abrasive Machining Basics Lean Deburring, Lean Finishing
• Fluidized bed technology develops complete envelopment of parts with loose abrasive
• Rotational movement of parts produces high intensity abrasive particle contact with part edges and surfaces to develop edge contour and surface finish
• Relatively small media and high speed rotation promote processing of intricate or complex geometries and even simple interior channels
Free abrasive method uses fluidized bed and part rotational forces
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INDUSTRY: Aerospace
PART: Turbine; Compressor Disks
PROBLEM: Reduce deburring timeand cost; develop edge-contour, develop isotropic surfaces, develop compressive stress
PROCESS(ES) REPLACED:hand-tools; pencil grinders
TURBOFINISH SOLUTION:Implement TAM Process withTF-Turbo-Abrasive Machine
TURBOFINISH PROCESS IMPROVEMENT:10 inch disk processing time reduced from 3 hrs to 3 min. Per part abrasive cost reduced to 0.15 each.20 inch disk processing time reduced from 3-10 hrs to 6 min.
Turbo Abrasive Machining Basics Lean Deburring Case Study
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TAM vs. Manual Deburring – Service Improvement, fatigue resistance TAM vs. Manual Deburring – Service Improvement, fatigue resistance
Also, destructive testing of steel plates:
Conventional ground plates fail after (1.1 – 1.5) * 104 cyclesTAM process plates fail after (3 – 3.75) * 104 cycles
COMPARISONS:
Fatigue Limit Value σ_1
Grinding = 250 + 43 MPa
TAM = 330 + 20 Mpa
Spin Test Results: (cycles)Disks with Manual treatment
Cracks appear: 2600 + 700
Disks destruct: 5685 + 335
Disks with TAM treatment
Cracks appear: 7300 + 700
Disks Destruct: 13090 + 450
IMPORTANTTAKE AWAYPOINT
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Understanding Part Performance: Current Condition vs. Target ConditionUnderstanding Part Performance: Current Condition vs. Target Condition
Typical Cast Surface Typical Isotropic Surface
Typical Ground Surface Typical Isotropic Surface