Turbo-Finish Presentation for AERODEF SME conference in Houston, TX March 9-11, 2017 Deburring/Finishing, Surface Coditioning

1. PRESENTED BY
High-Speed Dry Spindle Deburring
and Finishing of Rotating Hardware
Dr. Michael Massarsky, President, Turbo-Finish Corporation
Dave Davidson, SME Deburring Technical Group,

2. Turbo-Abrasive
Machining and
Finishing
• Turbo-Abrasive Machining
(TAM) is a mechanical
deburring and finishing method
originally developed primarily
to automate edge finishing
procedures on complex
rationally oriented and
symmetrical aerospace engine
components
• Since its inception this method
of utilizing fluidized free
abrasive materials has
facilitated significant reductions
in the amount of manual
intervention required to deburr
large components by these
manufacturers
• Additionally, the process has
also proved to be useful in edge
and surface finishing a wide
variety of other non-rotational
components by in incorporating
these components into fixing
systems

3. Automated Deburring, Edge-Contour, Isotropic Finishing

6. Turbo-Abrasive Machining
(TAM) and Finishing
• Turbo-Finish is capable of running both rotating and
large volumes of smaller non-rotating parts in dry
spindle finish applications.
• (1) Dry operation. Turbo-Finish produces both
smoothing and polished surface effects with an entirely
dry operation. No wet waste is generated.
• (2) Horizontal Spindle Operation. Unlike other spindle
finish methods, the Turbo-Finish method utilizes
horizontal spindles, accommodating several parts or
part fixtures on the same spindle or on multiple
processing spindles.
• (3) Rapid edge and surface finish development.
Unlike other spindle-finish methods, spindle rotating
speeds in the hundreds and even thousands rpm are
possible because of Turbo-Finish’s unique media
delivery system.
• (4) Economical Tooling and Media. Much of the work-
holding tooling can be made from various plastic
materials and still maintain extended service life.

7. Industry Segment Examples
• INDUSTRIES:
• Aerospace Industry
• turbine and compressor discs
• turbine blades
• turbine impellers
• turbine blisks
• gears for wind power turbines
• (up to 40” in diameter)
• Cutting tools
• taps
• drills
• hobs
• milling cutters
Power generation Industry
Turbine discs
(up to 46” in diameter)
Automobile industry
automotive transmission
gears
clutch plates
Other applications
boat or ship propellers
medical parts, i.e. bone screws
jewelry parts
MATERIALS:
Carbon Steel
Stainless Steel
Bronze
Aluminum
Titanium
Waspalloy
Inconel
Nickel Alloys
Ceramic Composites

8. 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 to polishing
media for developing low micro-
inch surfaces

9. 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

10. Significant Process
Characteristics
• 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

11. Small diameter
complex parts
• 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 less than sixty
seconds

12. Dry Abrasive and
Polishing Media
Materials
• Abrasive Material such as Aluminum Oxide,
Zirconium Oxide
• Polishing and Micro-Finishing media such as
soft granulates to develop lower micro-inch
surfaces and develop refined reflective
surfaces to assist visual inspection
• Surface roughness pattern orientation to
vector
• Abrasive particle size can vary
• Abrasive composition can vary
• Multiple processes on the same part can
used successively finer abrasive materials to
achieve very fine edge and surface finishes
when required

13. Micro-
Finishing
• Secondary
operations include
processing with
dry polishing
media to produce
refined surfaces to
better facilitate
visual inspection

14. Dry Micro-
Finishing
• [Ra = 11.8 micro-inch]
• Surface and edge
finish effects can be
further improved
when multiple turbo-
abrasive machining
steps utilizing
sequentially finer
abrasive materials.
• This disc photo and
graph shows surfaces
after two sequential
TAM cycles.

15. Extreme
Deburring
and Finishing
• Difficult Burr, Edge
and Surface
Conditions
Addressed
• Difficult
Geometries
Accessed
BEFORE

16. Extreme
Deburring
and Finishing
• Difficult Burr, Edge
and Surface
Conditions
Addressed
• Difficult
Geometries
Accessed
AFTER

17. Extreme
Deburring and
Isotropic
Surface
Finishing
• Sharp edge features
with significant burr
condition
• Non-isotropic surface
finish with Gaussian
positively skewed
surface
• Crack propagation
points?
Before

18. Extreme
Deburring and
Isotropic
Surface
Finishing
• Sharp edged features
and burrs removed
• Non-isotropic surface
finish with Gaussian
positively skewed
machined or ground
surface replaced with
isotropic surface finish
with neutral surface
profile skews
• Automated dry
machine cycle
AFTER

19. Turbo-Finish Case
Study – BEFORE
Rapid Automated
Aerospace Component
Deburring
• Photo shows disk segment
prior to processing with
Turbo-Finish
• Note heavy burr condition
in the slot edges
• Note also machining
marks on features

20. After Turbo-
Finish
Processing
• MACHINE:
Turbo-Finish Model
TF-500
• Cycle Time:
Six Minutes
• Finishing Media:
36 Mesh Dry Abrasive
Grain
• Horizontal Spindle
Rotation
• Fluidized bed media
delivery

22. Turbo-Finish
Part Operations
Before TAM
• Compressor Disks
• Note: machined or
ground surfaces prior
to high-speed dry
finishing
• Note: Burr condition
and sharp edged
features

23. Turbo-Finish Part
Operations
After TAM
Processing
• Compressor Disks
• Note: machined or
ground surfaces now
replaced by isotropic
surfaces
• Note: Burr condition and
sharp edged features have
been replaced with
consistent and uniform
edge-contour

24. Dry, High-
Speed Gear
Deburring
• Prior to TAM
processing,
• Burrs
• Sharp edge condition
• Non-isotropic surface
condition

25. Dry High-
Speed Gear
Deburring
• After TAM processing
• Burrs Removed
• Sharp edge condition
replaced with contour
• Manual deburring
eliminated
• Reject/rework rates
reduced close to zero
• Isotropic surface
development

26. Automated Disk
Finishing
• Several advantages when
compared with other mechanical
finishing technologies
• Automation and mechanization of
deburring for complex rotating
parts. Edge contour, surface-
finishing improvement and
compressive stresses developed
on parts SIMULTANEOUSLY
• Manual process consuming many
hours are reduced to automated
machining cycles of only a few
minutes
• High flow of dry abrasive particles
allows penetration of an abrasive
action on many difficult to access
part areas
• Low energy consumption (unlike
blasting, peening or other
pressure or impact processes)
• Low consumable cost. The current
track record indicates that
abrasive costs per disk are
approximately $0.15 per disk for
10 inch disks, and $0.50 for 20
inch disks

27. TAM Features and Benefits
• The TF technology, in addition to producing a good radius
on the feature can create an isotropic surface effect. The
isotropic surface effect minimizes potential crack
propagation points and improves stress equilibrium
among part features. All common machining and manual
finishing methods produce non isotropic but linear
characteristics. This contributes to tension concentration
of the sharp surface peaks and easier crack propagation
• The microimpact of abrasive small particles and a high
velocity of the part produce beneficial compressive
stresses and also improve the surface integrity and fatigue
resistance of many types of critical components
• As TF is a cold process, it causes no structural phase
transformation on the surface. The TF technology
increases the service life from 30% to 100%, depending of
the part material (nickel alloy, stainless steel, titanium

30. Turbo-Finish
Process
Development
Laboratories
• Process Development
• Process Engineering
• Sample Processing
• Beta-Testing
• 917.518.8205
• michael@turbofinish.com