Turbo finish technology v2.2

Turbo-Finish Technology
TURBO-FINISH APPLICATIONS
© 2016. Turbo Finish Corporation. All rights reserved.
Dr. Michael Massarsky | TURBOFINISH CORP. | michael@turbofinish.com
David A. Davidson | SME MMR Tech Community | dryfinish@gmail.com
1

 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
2

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 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)
3

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
MATERIALS:
Carbon Steel
Stainless Steel
Bronze
Aluminum
Titanium
Waspalloy
Inconel
Nickel Alloys
Ceramic
Composites
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
INDUSTRY SEGMENT EXAMPLES
4

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.
APPLICATIONS – A PARTIAL ABBREVIATED LIST
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Turbo-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
6

Turbine Disc Before and After TAM
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 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
8

 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
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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
10

 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.
11

 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
12

 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
13

 Secondary operations include
processing with dry polishing
media to produce refined surfaces
to better facilitate visual inspection
SEQUENTIAL PROCESSING
14

.015
.008
TAM RADIUS DEVELOPMENT
 Edge radius development on
broach slot edge developed on
18.7 inch [475mm] Turbine Disc
15

BEFORE AND AFTER
ISOTROPIC SURFACE FINISH
16

 Improvement seen in
metal fatigue limit and
contact rigidity over
conventional methods
TAM METAL IMPROVEMENT
17

 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
18

19

20

Turbo-Finish Part Operations
Compressor Disk
BEFORE AFTER
21

Difficult Geometries Accessed
BEFORE AFTER
22

 Large Variety of disk
configurations can be
processed at the same
Turbo-Finish installation
23

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 Study
RAPID AUTOMATED AEROSPACE DEBURRING
24

 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 - BEFORE
25

 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 - AFTER
26

After
Turbo-Finish
27

Slot Edge Detail
BEFORE AFTER
28

High Performance Gas Turbine Rotating Hardware
29

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.
30

[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
31

32

Impeller Burr removal, Edge-Contour
33

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 life
Cold hardening of foil surfaces
Burr removal and radiusing root edges SIMULTANEOUSLY
Turbine Blades
34

 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
POLISHING AND SUPERFINISHING OPERATIONS
35

Gears and Other Rotating Part Types
 High-Speed Spindle-Finish Processing with Dry-Processing
36

37

Before TAM
38

After TAM
39

NON-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
40

FIXTURED 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
41

Heat 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
42

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
Piezoelectric Ceramic Plate
43

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 Machines
TURBO-ABRASIVE MACHINING
CENTER
– Model No. 522
44

Turbo-Finish Machines
NEW TURBO-FINISH MACHINING
CENTER
– Model TF-522-SS
State of the Art Automated Deburring for
Gas Engine Rotating Hardware.
45

 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
46

 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
47

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