Improving Performance and Life of Aerospace Engine Hardware by Developing Isotropic Surfaces with

Turbo-Abrasive Machining

SOCIETY OF MANUFACTURING ENGINEERSAERODEF Confecrence, Long Beach. CA Mar 9, 2013 Dr. Michael Massarsky; President, Turbo-Finish Corporation.

David A. Davidson, Technical Group Chair Deburring, Edge-Finish, Surface Conditioning Technical Group

Machining/Metal Removal Technical Community

Turbo Abrasive Machining – Lean Deburring

This abrasive fliudized bed machining center is capable of processing 20 inch (500mm) disks

Turbo Abrasive Machining in Motion…

INDUSTRY: Aerospace

PART: Turbine; Compressor Disks

PROBLEM: Reduce deburring timeand cost; develop edge-contour, develop isotropic surfaces, develop compressive stress

PROCESS(ES) REPLACED:hand-tools; pencil grinders

TURBOFINISH SOLUTION:Implement TAM Process withTF-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.

Turbo Abrasive Machining Basics Lean Deburring Case Study

TAM vs. Manual Deburring Service Improvement, fatigue resistance

Also, destructive testing of steel plates:

Conventional ground plates fail after (1.1 – 1.5) * 104 cyclesTAM process plates fail after (3 – 3.75) * 104 cycles

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

IMPORTANTTAKE AWAYPOINT

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

Centrifugal Barrel Finishing – High Intensity Surface Finishing in a non-fixtured environment

• High Speed Processing• Quick-change over• High-Mix, Low Volume capability

Understanding Part Performance: Current Condition vs. Target Condition

High Magnification electron microscope photos – before and after

As Cast After Centrifugal Finish

As ground After Centrifugal Finish

Out from underneath the Microscope Parts processed with High Intensity Finishing…

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…

Turbo Abrasive Machining – Lean Deburring

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

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

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.