High Speed and High Intensity mechnical finishing methods change the face of finishing within American manufacturing

1. Meeting the
Lean Deburring
Challenge
SOCIETY OF MANUFACTURING ENGINEERS
David A. Davidson; Michael Massarsky Ph.D;
Jack Clark
Deburring, Edge-Finish, Surface Conditioning Technical Group
Lean2Green Resource Center
EASTEC – Springfield MA May 20, 2009

2. Meeting the Lean Deburring Challenge
Terry Begnoche, SME Manager for Lean Activities and Programming adjusts
microphone clip for Dave Davidson, SME DESC Group Chair at the SME
Lean2Green Conference Program area

3. Batch and Queue –
Typical Hand Deburr
Stage 1 - Production in Functional Departments
A
B
C

4. Batch and Queue Hand Deburring at
MacKay before Lean Deburring
implementation with Centrifugal

5. Meeting the Lean Deburring Challenge
This presentation ws developed with
materials provided by members of the
Deburring, Edge and Surface
Conditioning Technical Group. One
of the technical committees that
comprise the Technical Community
Network of the Society of Manufact-
uring Engineers.
A major focus of the Society in
recent years has been to proliferate
LEAN by providing resources as well
as educational and certification
opportunities for those who wish to
utilize LEAN in their production and
business processes. This presentation
was developed to highlight how
LEAN and mass finishing
technologies can be meshed….

6. Continuous Flow
Stage 4 - Compact Cell w/One-Piece Flow
& Separation Member & Machine
A
B
C

7. CBF machine center of cell

8. High Speed Finishing with CBF cellular flow

9. The High energy centrifugal principle
Rapid turret rotation and rapid barrel counter-rotation
• High Speed Processing
• Quick-change over
• High-Mix, Low Volume
capability

10. Parts processed in bulk
MacKay Manufacturing utilizes
centrifugal finishing as a part of
Its lean implementation

11. Compartmentalization for critical parts

12. Centrifugal Barrel Processing
Replacement of Hand Deburr
and Finish

13. Standardized Work – Visual Aid

14. High pressure, high force processing
with small media replaces batch and
queue hand processing.

15. Deburring Cell – visual aid
Competency at a glance

16. Visual Aids – tracking the high mix –
low volume flow of critical and premium
parts at MacKay Manufacturing

17. Turbo Abrasive Machining – Lean Deburring
This machine was built to deburr and
edge-contour turbine and compressor
disks up to 20 inches in diameter [500mm]

18. Turbo Abrasive Machining – Lean Deburring
Dr. Michael Massarsky (below) inventor of
the Turbo-Abrasive Machining method which
promotes rapid, single piece continuous flow
deburring of large complex rotational parts

19. Turbo Abrasive Machining Basics
Lean Deburring, Lean Finishing
Free abrasive method uses fluidized
bed and part rotational forces
• 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

20. Turbo Abrasive Machining Basics
Lean Deburring Case Study
INDUSTRY: Aerospace
PART: Turbine; Compressor Disks
PROBLEM: Reduce deburring time
and cost; develop edge-contour, develop
isotropic surfaces, develop compressive
stress
PROCESS(ES) REPLACED:
hand-tools; pencil grinders
TURBOFINISH SOLUTION:
Implement TAM Process with
TF-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.

21. Turbo Abrasive Machining – Lean Deburring
Michael Massarsky Ph D.
Inventor of the Turbo-Finish
method . In a “lean” context
his process has brought
single piece continuous flow
processing capability to
deburring and edge finish
challenges on large rotating
parts in the aerospace
industry. Additionally, the
method has shown to
improve service life on
critical aerospace hardware.
One jet engine manufacturer
found its hardware life was
improved by 50% in
rigorous spin pit testing…

22. TAM vs. Manual Deburring
Service Improvement, fatigue resistance
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
IMPORTANT
Also, destructive testing of steel plates: TAKE AWAY
Conventional ground plates fail after (1.1 – 1.5) * 104 cycles POINT
TAM process plates fail after (3 – 3.75) * 104 cycles

23. 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

24. Understanding Part Performance:
Current Condition vs. Target Condition
Dave Davidson and Jack Clark, SME members involved with the
Deburring and Edge/Surface Conditioning Technical Group

25. Understanding Part Performance:
Current Condition vs. Target Condition
As Cast After Centrifugal Finish
As ground After Centrifugal Finish
High Magnification electron microscope photos – before and after

26. Jack Clark of Surface Analytics is a nationally recognized authority on surface metrology
and the understanding of surface characterization relationships to part performance and
longevity. Jack became interested in surface finish for performance when as a leader of a
Formula One Racing Team , he could extend the life of critical engine hardware from one
race to a year. Using electron microscopes and optical interferometry Jack assists
manufacturers develop surface finishes that provide dramatic increases in service life.

27. Out from underneath the Microscope
Parts processed with Lean Finishing…