Meeting the

Lean Deburring

Challenge

SOCIETY OF MANUFACTURING ENGINEERS

David A. Davidson; Michael Massarsky Ph.D;

Jack ClarkDeburring, Edge-Finish, Surface Conditioning Technical Group

Lean2Green Resource Center

EASTEC – Springfield MA May 20, 2009

Meeting the Lean Deburring Challenge

Terry Begnoche, SME Manager for Lean Activities and Programming adjusts

microphone clip for Dave Davidson, SME DESC Group Chair at the SME

Lean2Green Conference Program area

A

B

C

Batch and Queue –

Typical Hand Deburr

Stage 1 - Production in Functional Departments

Batch and Queue Hand Deburring at

MacKay before Lean Deburring

implementation with Centrifugal

Meeting the Lean Deburring Challenge

This presentation ws developed with

materials provided by members of the

Deburring, Edge and Surface

Conditioning Technical Group. One

of the technical committees that

comprise the Technical Community

Network of the Society of Manufact-

uring Engineers.

A major focus of the Society in

recent years has been to proliferate

LEAN by providing resources as well

as educational and certification

opportunities for those who wish to

utilize LEAN in their production and

business processes. This presentation

was developed to highlight how

LEAN and mass finishing

technologies can be meshed….

A

B

C

Continuous Flow

Stage 4 - Compact Cell w/One-Piece Flow

& Separation Member & Machine

CBF machine center of cell

High Speed Finishing with CBF cellular flow

The High energy centrifugal principle

Rapid turret rotation and rapid barrel counter-rotation

• High Speed Processing

• Quick-change over

• High-Mix, Low Volume

capability

Parts processed in bulk

MacKay Manufacturing utilizes

centrifugal finishing as a part of

Its lean implementation

Compartmentalization for critical parts

Centrifugal Barrel Processing

Replacement of Hand Deburr

and Finish

Standardized Work – Visual Aid

High pressure, high force processing

with small media replaces batch and

queue hand processing.

Deburring Cell – visual aid

Competency at a glance

Visual Aids – tracking the high mix –

low volume flow of critical and premium

parts at MacKay Manufacturing

Turbo Abrasive Machining – Lean Deburring

This machine was built to deburr and edge-contour turbine and compressor

disks up to 20 inches in diameter [500mm]

Turbo Abrasive Machining – Lean Deburring

Dr. Michael Massarsky (below) inventor of

the Turbo-Abrasive Machining method which

promotes rapid, single piece continuous flow

deburring of large complex rotational parts

Turbo Abrasive Machining Basics

Lean Deburring, Lean Finishing

• Fluidized bed technology develops complete envelopment of parts with loose abrasive

• 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

Free abrasive method uses fluidized

bed and part rotational forces

INDUSTRY: Aerospace

PART: Turbine; Compressor Disks

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

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

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

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

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

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

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.

Out from underneath the Microscope

Parts processed with Lean Finishing…