Turbo finish technology v2.2

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Turbo-Finish Technology

TURBO-FINISH APPLICATIONS

© 2016. Turbo Finish Corporation. All rights reserved.

Dr. Michael Massarsky | TURBOFINISH CORP. | [email protected] A. Davidson | SME MMR Tech Community | [email protected]

mailto:[email protected]

mailto:[email protected]

2 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

INTRODUCTION


3Turbo-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 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.

Turbo-Abrasive Machining (TAM)


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INDUSTRIES:Aerospace Industryturbine and compressor discsturbine bladesturbine impellersturbine blisksgears for wind power turbines (up to 40” in diameter)Cutting toolstapsdrillshobsmilling cutters

MATERIALS:

Carbon SteelStainless SteelBronzeAluminumTitaniumWaspalloyInconelNickel AlloysCeramic Composites

Power generation IndustryTurbine discs (up to 46” in diameter)Automobile industryautomotive transmissiongearsclutch platesOther applications boat or ship propellersmedical parts, i.e. bone screwsjewelry parts

Turbo-Finish TechnologyINDUSTRY SEGMENT EXAMPLES


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Turbo-Finish is capable of running both rotating and large volumes of smaller non-rotating parts in dry spindle finish applications. Some of the typical legacy applications include:Turbo-charger Rotors: An eight spindle machine was built for deburring and edge-finishing turbo-charger rotors. The machine replaced manual methods and was capable of processing hundreds of rotors per shift.Helicopter Engine Disks: Turbo-Finish was used for deburring, edge-finishing helicopter turbine disks.Hand Tools: Hand-tools such as pliers, cutters and scissors. Items were run on disk fixtures in a completely dry abrasive smoothing and heat treat scale removal process.Bearing Races: Turbo-Finish deburred and smoothed pocket structures on bearing races.Piston Rings: Turbo-Finish developed an isotropic scratch pattern on the rings to provided for better lubricant dispersion and retention.Diamond Cutting Wheels: A manufacturer utilized Turbo-Finish Machines to process diamond cutting wheels used on the stone cutting industry. The Turbo-Finish process was used to open and expose the grit attached to the wheels for better cutting efficiency lubricant dispersion and retention.Automobile Hub-Caps: Turbo-Finish was used for producing pre-plate finishes on hub-caps with a completely dry-process.Clipper Blades: Clipper blades for sheep-shearing. 168 mounted on a disk fixture. Removed edge micro-burrs and heat treat scale in one operation, completely dry process.

Turbo-Finish TechnologyAPPLICATIONS – A PARTIAL ABBREVIATED LIST


6Turbo-Abrasive Machining and Finishing

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

TURBO-FINISH APPLICATIONS


7Turbine Disc Before and After TAM



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

TAM BASICS



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

SIGNIFICANT PROCESS CHARACTERISTICS



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© 2016. Turbo Finish Corporation. All rights reserved.


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 OR FIXTURE OPERATIONS© 2016. Turbo Finish Corporation. All rights reserved.


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


MULTIPLE SPINDLE OPERATION© 2016. Turbo Finish Corporation. All rights reserved.

13Turbo-Abrasive Machining and Finishing 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

MEDIA MATERIALS



Secondary operations include processing with dry polishing media to produce refined surfaces to better facilitate visual inspection

SEQUENTIAL PROCESSING


.015

.008

Turbo-Abrasive Machining and FinishingTAM RADIUS DEVELOPMENT

Edge radius development on broach slot edge developed on 18.7 inch [475mm] Turbine Disc


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BEFORE AND AFTER

ISOTROPIC SURFACE FINISH



Improvement seen in metal fatigue limit and contact rigidity over conventional methods

TAM 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

TAM METAL IMPROVEMENT


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21Turbo-Finish Part OperationsCompressor Disk

BEFORE AFTER© 2016. Turbo Finish Corporation. All rights reserved.

22Turbo-Finish Part OperationsDifficult Geometries Accessed


23Turbo-Finish Part Operations Large Variety of disk

configurations can be processed at the same Turbo-Finish installation


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Turbo-Finish and Turbo-Abrasive machining is an automated method for rapid deburring and developing edge-contour on rotating turbine engine hardware.

The following slides show the before and after condition of a disk processed in a Turbo-Finish Model TF-500 machine for six minutes.

Turbo-Finish Case StudyRAPID AUTOMATED AEROSPACE DEBURRING


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Photo shows disk segment prior to processing with Turbo-Finish

Note heavy burr condition in the slot edges

Note also machining marks on features

Turbo-Finish Case Study - BEFORERAPID AUTOMATED AEROSPACE DEBURRING


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MACHINE: Turbo-Finish Model TF-500

Cycle Time: Six Minutes

Finishing Media: 36 Mesh Dry Abrasive Grain

Horizontal Spindle Rotation Fluidized bed media delivery

Turbo-Finish Case Study - AFTERRAPID AUTOMATED AEROSPACE DEBURRING


27AfterTurbo-Finish


28Turbo-Finish Part OperationsSlot Edge Detail


29Turbo-Finish Part OperationsHigh Performance Gas Turbine Rotating Hardware


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These profilometer tests show surface TAM surface modifications to extremely rough surfaces.In this case, a machined cast iron gear wheel was processed in under ten minutes to produce an Ra micro-inch reading of 48 from an initial surface profile of 136. Secondary processing with special polishing media can reduce surface values even further, as shown in the tape TAM 2.

TAM Processing of Extreme Surface Conditions

BEFORE TAM 1 TAM 2 © 2016. Turbo Finish Corporation. All rights reserved.

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[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 different TAM cycles.

TAM Processing of Extreme Surface Conditions TURBINE DISK AFTER TAM1 and TAM2


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33Turbo-Finish Part OperationsImpeller Burr removal, Edge-Contour


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INDUSTRY: AEROSPACE

PART: Turbine Blades

PROBLEM: Improve Blade Surface Finish, increase service life and add to metal fatigue resistance

PROCESS(ES) REPLACED: Vibratory and Peening processes

TURBOFINISH SOLUTION: Planetary TAM Operation

TURBOFINISH PROCESS IMPROVEMENT: 2 times improvement in Surface Ra 20-25% improvement in fatigue lifeCold hardening of foil surfacesBurr removal and radiusing root edges SIMULTANEOUSLY

Turbo-Finish Case StudyTurbine Blades


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In addition to utilizing abrasive granule media for deburring, edge-contour and smoothing, Turbo-Finish can also use soft granulate materials (such as that shown above) to produce super-finished or micro-polished surface effects

Turbo-Finish Part OperationsPOLISHING AND SUPERFINISHING OPERATIONS


36Turbo-Finish Part OperationsGears and Other Rotating Part Types

High-Speed Spindle-Finish Processing with Dry-Processing


37Turbo-Finish Part Operations


38Before TAM


39After TAM


40Turbo-Finish Part OperationsNON-ROTATING PARTS

Although more widely known as a method for deburring and finishing rotating hardware, Turbo-Finish is also capable of processing non-rotational parts

In this capability Turbo-Finish is not unlike common mass finishing methods such as drag finishing, spin-finishing and spindle finishing. It has some major differences and advantages over these methods


41Turbo-Finish Part OperationsFIXTURED DESCALING OPERATIONS

Turbo-Finish is capable of running large volumes of smaller non-rotating parts in applications such as this one where 186 pieces were mounted on a disk fixture and processed to remove sever heat treat scale


42Turbo-Finish Part OperationsHeat Treat scale removal in a rapid dry process

Turbo-Finish is capable of running both rotating and large volumes of smaller non-rotating parts in dry spindle finish applications such as this one


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INDUSTRY: Electronics

PART ID: Piezoelectric Ceramic Plate, Magnetic Recording Heads

PROBLEM: Internal channels must be cleared of debris

SOLUTION: Parts were mounted on disk fixture

PART QUANTITIES per process: 100+

RESULT: Fine mesh Turbo-Finish media cleared channels of debris, developed uniform surfaces

Turbo-Finish Case StudyPiezoelectric Ceramic Plate


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This Model TF-522 Turbo-Abrasive Machining Center is capable of processing spindle mounted parts in high-speed dry finishing process called Turbo-Finish. The fixtured parts are processed through fine abrasive and when required, polishing grits to deburr, edge-contour and develop needed surface finishes in an entirely dry process, eliminating the need for wet waste treatment and disposal of an effluent stream common to most other mass media finishing processes. This machine processes aerospace disks up to 500mm or 20 inches in diameter.

Turbo-Finish MachinesTURBO-ABRASIVE MACHINING CENTER – Model No. 522


45Turbo-Finish MachinesNEW TURBO-FINISH MACHINING CENTER – Model TF-522-SS

State of the Art Automated Deburring for Gas Engine Rotating Hardware.


46 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 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)

Turbo-Finish Features And Benefits


47 Uniformity/Consistency: Unlike single point of contact methods (manual, robotic, chamfering by milling) TF

produces edge contour on part features simultaneously and identically. Not only are beneficial compressive stresses imparted to the features, but as part features are treated identically, an overall stress equilibrium is set in the part. The tooth edge features would be edge contoured and stressed identically

On our laboratory testing machine we remove the burrs, developing needed edge (radius formation up to 0.5-0.6mm) and surface requirements from Rmax. 140-150m/inch to Ra 10-15m/inch but as most of the customers are aerospace they do most of their testing inside to meet their specific concerns, and each of them are different

Tooling: The tooling which clamps the rotating parts on the spindle is made from nylon or similar material. The material is inexpensive, and it is very inexpensive to machine. Unlike metal tooling it is very resistant to abrasive wear and is lightweight. Placing part pieces on the tooling is simplicity itself. Tooling can be designed to mask certain part areas so that the abrasive effect is concentrated in desired areas only

Safety: As the process has the ability to drastically reduce manual deburring, some manufactures have been able to justify the equipment with the reduction of liability or risk for long term repetitive motion injury cases alone

TF process was able to eliminate an internal spline burr that no other process could achieve. The standard TF process was able to meet all of edge break requirements of a major company while leaving a sharp edge on the knife edge seal rings

The Turbo-Finish technology has been given FAA approval Companies that have been using the TF technology for years report it to be a very beneficial process

Turbo-Finish Features And Benefits


Engineering

Turbo finish technology v2.2