Turbo abrasive machining and finishing

Turbo-Abrasive Machining and
Finishing
SME MMR ISOTROPIC SURFACE FINISH RESEARCH PROJECT
Dr. Michael Massarsky | TURBOFINISH CORP. | michael@turbofinish.com
David A. Davidson | SME MMR Tech Community | dryfinish@gmail.com
1

Turbo-Abrasive Machining and Finishing
 TAM BASICS
 Fluidized bed technology develops complete
envelopment of parts with free abrasive media
 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
 A wide variety of abrasive and polishing media
can be utilized from heavy abrasives
topolishing media for developing low micro-
inch surfaces
SME MMR Isotropic Surface Finish Research Project
2

 Turbo-Finish Applications
 Deburring, Edge and Surface Conditioning,
Metal Improvement
 Turbine and Compressor Disks
 Rotational Oriented Static Hardware
 Gears, Impellers, Rotors, Sprockets, Turnings
 Automotive: Piston Rings; Turbocharger
rotors
 Textile, Pump, Marine Industry rotating parts
 Non-Rotating Parts with disk fixturing
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 Significant Process Characteristics
 Rapid machine cycles replace tedious manual
processes
 Intricate part geometries accessed (small
media – high intensity rolling or glancing
contact)
 Completely DRY abrasive, polishing or non-
abrasive operation, NO WET WASTE DISPOSAL
 Micro-textured surfaces are excellent substrate
for coatings
 Metal surface improvement; compressive stress
effects, enhanced metal fatigue resistance
 No part-on-part contact or impingement
 Disk prior to TAM processing
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 Rapid simple operation well suited to single
piece continuous flow and cell operations
 Very modest tooling requirements
 Primarily external edge and surface
conditioning method. Some simple interior work
possible.
 Both rotating and fixtured non-rotating parts
can be processed.
 Isotropic surfaces generated
 Feature-to-feature, part-to-part and lot-to-lot
uniformity not achievable with manual
methods Disk after TAM Processing
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 HORIZONTAL SPINDLE OPERATION
 Multiple parts can be fixtured on a single spindle
 Unique abrasive delivery system (fluidized bed)
assures uniform processing of all parts on the
spindle
 The abrasive fluidized bed permits high-speed
rotational operation. Speeds of 800- 2000 rpm are
commonly specified.
 The takt time (floor-to-floor) for running these disks
was calculated to be 60 seconds
 Multiple part operation
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 Smaller diameter parts can also be run in
multiple spindle equipment
 These rotor parts were run in a dry abrasive
process in an eight spindle machine.
 Takt time per part (floor to floor) was 38
seconds
 Multiple spindle operation
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 Significant Process
Characteristics
 Small media operation permits
process to access difficult
geometries
 Small dry abrasive media can
reach intricate details that
poses a problem for larger
performed media shapes
common to other types of mass
finishing operations.
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 Significant Process
Characteristics
 Significant radius and edge-
contour developed on slot
areas of aerospace turbine
and compressor engine disks
Dr. Michael Massarsky | TURBOFINISH CORP. |
michael@turbofinish.com
David A. Davidson | SME MMR Tech Community |
dryfinish@gmail.com
9

 Rotationally oriented parts are fixtured
and clamped at the end of a spindle
and rotated around the spindle axis
 Non-rotational parts are processed by
fixturing the part on disk-like holding
fixtures
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 PROCESS CONTROLLED
VARIABLES
 Rotational Speed
 Time
 Surface roughness
pattern orientation to
vector
 Abrasive particle size
 Abrasive composition
SME MMR Isotropic Surface
Finish Research Project
David A. Davidson | SME MMR Tech
Community | dryfinish@gmail.com
11

 HIGH-SPEED and RAPID:
 Deburring
 Edge-Contour
 Isotropic Surface
Development
 Compressive Stress
Equilibrium
 Surface plateauing or
planarization for
converting positively
skewed machined
surfaces to negatively
skewed surfaces
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 HIGH-SPEED and RAPID
PROCESSING:
 Edge-Contour effects are
often developed in 60 – 120
second cycles
dryfinish@gmail.com
13

 BEFORE and AFTER
COMPARISON
 Edge-Contour and
Isotropic Surfaces are
often developed in 60 –
120 second cycles
SME MMR Isotropic Surface Finish
Research Project
dryfinish@gmail.com
14

COMPARISON
 Rapid deburring and
material removal
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COMPARISON
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 COMPARISON
 Improvement seen in
metal fatigue limit and
contact rigidity over
conventional methods
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 METAL IMPROVEMENT
 TAM processing produced
superior metal fatigue
resistance by developing a
compressive stress
equilibrium in the disk
components
 Conventional machined
surfaces were converted to
isotropic surfaces by blending
in machining marks or
notches that are potential
crack propagation points
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 SEQUENTIAL
PROCESSING
 Secondary operations
include processing with
dry polishing media to
produce refined
surfaces to better
facilitate visual
inspection
SME MMR Isotropic Surface
Finish Research Project
David A. Davidson | SME MMR Tech Community
| dryfinish@gmail.com
19

Turbo abrasive machining and finishing

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