Copyright 2001 Society of Manufacturing Engineers. FUNDAMENTAL MANUFACTURING PROCESSES Deburring Processes NARRATION (VO):

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1 FUNDAMENTAL MANUFACTURING PROCESSES Deburring Processes SCENE 1. CG: Mass Finishing white text centered on black SCENE 2. CG, SUPER: Mass Finishing tape 584, 01:18:55-01:19:20 mass finishing tape 588, 05:06:37-05:06:49 media abrading and scrubbing workpieces MASS FINISHING IS A LOOSE-ABRASIVE TECHNOLOGY USED TO MECHANICALLY FINISH MANY WORKPIECES SIMULTANEOUSLY. WORKPIECES ARE PLACED IN VESSELS OF ROTATING, CONSUMABLE MEDIA AND, TYPICALLY, WITH WATER OR A WATER-SOLUBLE COMPOUND. THE MEDIA ABRADE AND SCRUB WORKPIECE EDGES AND SURFACES WITH, USUALLY, GENTLE FINISHING ACTION. THE MEDIA ALSO KEEPS THE WORKPIECES SEPARATED. SCENE 3. tape 603, 13:05:15-13:05:27 mass finished workpieces being washed after processing AFTER FINISHING, WORKPIECES ARE WASHED, PERHAPS TREATED WITH RUST INHIBITORS, AND DRIED. SCENE 4. tape 586, 03:10:40-03:10:55 mass finishing, parts being polished MASS FINISHING NOT ONLY DEBURRS, BUT CAN CLEAN, DESCALE, BRIGHTEN, POLISH OR SURFACE-FINISH WORKPIECES. SCENE 5. tape 605, 11:10:20-11:10:40 ground corncobs tape 605, 11:08:20-11:08:40 preformed ceramic media tape 605, 11:07:20-11:07:40 preformed hardened steel tape 605, 11:06:20-11:06:40 preformed resin-bonded plastics THE PRIMARY TYPES OF MEDIA USED IN MASS-FINISHING INCLUDE: AGRICULTURAL PRODUCTS - SUCH AS GROUND CORNCOBS, AND NUT SHELLS; PREFORMED CERAMIC MEDIA - SUCH AS PORCELAIN MIXED

2 WITH ALUMINA OR SILICON CARBIDE; PREFORMED HARDENED STEEL MEDIA; AND PREFORMED RESIN-BONDED PLASTICS - WHICH INCLUDE ABRASIVES MOLDED INTO POLYESTER OR UREA- FORMALDEHYDE RESINS. SCENE 6. tape 588, 05:06:56-05:07:09 mass finishing using preformed media tape 605, 11:04:10-11:04:20 preformed media, triangle shaped tape 605, 11:05:10-11:05:20 preformed media, cone shaped tape 605, 11:04:40-11:04:50 preformed media, cylinder shaped tape 605, 11:05:40-11:05:50 preformed media, pyramid shaped tape 605, 11:01:10-11:01:20 preformed media, sphere shaped tape 605, 11:02:40-11:02:50 preformed media, elbow shaped tape 605, 11:02:10-11:02:20 preformed media, three pointed stars shaped PREFORMED MEDIA RANGES IN A VARIETY OF SIZES AND COME IN A MULTITUDE OF SHAPES, INCLUDING: TRIANGLES, CONES, CYLINDERS, PYRAMIDS, SPHERES, ELBOWS, AND THREE-AND FOUR-POINTED STARS. SCENE 7. tape 587, 04:03:40-04:03:48 vibratory finishing CG, SUPER: Vibratory Finishing tape 445, 12:30:18-12:30:30 barrel or rotary tumbling CG, SUPER: Barrel/Rotary Tumbling tape 587, 04:15:16-04:15:22 disk centrifugal finishing CG, SUPER: Centrifugal Disk Finishing tape 591, 07:17:09-07:17:20 barrel centrifugal finishing CG, SUPER: Centrifugal Barrel Finishing tape 591, 07:19:03-07:19:10 spindle finishing CG, SUPER: Spindle Finishing MASS-FINISHING PROCESSES INCLUDE: VIBRATORY FINISHING..., BARREL, OR ROTARY TUMBLING..., CENTRIFUGAL DISK FINISHING..., CENTRIFUGAL BARREL FINISHING..., AND SPINDLE FINISHING. SCENE 8. CG, SUPER: Vibratory Finishing tape 586, 03:06:04-03:06:30 zoom out, batch vibratory finishing VIBRATORY FINISHING IS SECOND ONLY TO MANUAL

3 tape 588, 05:01:32-05:01:38 continuous vibratory finishing DEBURRING IN INDUSTRY WIDE USE. VIBRATORY FINISHING IS USED FOR CLEANING, DEBURRING, DEFLASHING, EDGE AND CORNER RADIUSING, AND STRESS RELIEVING. ALL SORTS OF WORKPIECES, METALLIC OR NONMETALLIC, CAN BE PROCESSED WITHOUT HANDLING IN EITHER BATCH..., OR CONTINUOUS ARRANGEMENTS. SCENE 9. tape 587, 04:16:30-04:16:40 wide, rectangular tub being used in vibratory finishing tape 584, 01:25:50-01:26:00 wide, media abrading and scrubbing workpieces tape 584, 01:25:26-01:25:40 c.u. zoom out, media abrading and scrubbing workpieces VIBRATORY FINISHING EQUIPMENT CONSISTS OF RECTANGULAR TUBS..., OR ROUND BOWLS WITH AN OPEN-TOP WORK CHAMBER FOR MEDIA, COMPOUND, WATER AND WORKPIECES. AS THE CHAMBER IS VIBRATED THE WORKPIECES ARE SCRUBBED AND PEENED BY THE MEDIA AND COMPOUND. SCENE 10. tape 584, 01:09:00-01:09:28 wide, tub type vibratory finishing, zoom into part tape 584, 01:22:20-01:22:28 wide, tub type vibratory finishing, zoom out THE TUB TYPE, USUALLY U-SHAPED WITH FLAT, PARALLEL ENDS, IS GENERALLY MOUNTED ON COIL OR RUBBER SPRINGS. LINERS, USUALLY POLYURETHANE, PREVENT TUB WEAR, REDUCE NOISE, RESIST CORROSION AND TRANSMIT MECHANICAL ENERGY TO THE MEDIA. SCENE 11. tape 588, 05:03:18-05:03:30 zoom out, spiral-bowl deburring tub being used in vibratory ROUND-BOWL DEBURRING TUBS ARE DOUGHNUT-SHAPED, AND PERMIT CONTINUOUS FLOW OF MEDIA AND WORKPIECES. THEY HAVE FLAT OR SPIRAL BOTTOMS AND ARE ALSO POLYURETHANE-LINED. SCENE 12. tape 592, 08:14:06-08:14:20 c.u., zoom out, part and media vibrating tape 584, 01:06:41-01:06:56 VIBRATION IS THE PRINCIPAL MACHINE VARIABLE.

4 c.u., zoom out, part and media vibrating VIBRATION AMPLITUDE RANGES UP TO (0.375) THREE HUNDRED AND SEVENTY FIVE THOUSANDTHS OF AN INCH OR NINE AND A HALF MILLIMETERS AND FREQUENCY FROM 800 TO 3600 VIBRATIONS PER MINUTE. SCENE 13. CG, SUPER: Metal-Removal Rates Surface Roughness Media Wear Rate FASTER SPEEDS AND/OR GREATER VIBRATION AMPLITUDE INCREASE METAL-REMOVAL RATES, SURFACE ROUGHNESS AND MEDIA WEAR RATE. SCENE 14. tape 587, 04:24:01-04:24:12 zoom out, media and workpieces being separated using screen tape 588, 05:23:48-05:23:58 media and workpieces being separated using magnetic separators tape 588, 05:12:44-05:12:57 media reintroduced into the machine tape 364, 01:18:36-01:19:03 media and parts loaded in containers, transferred to distant separator MEDIA AND WORKPIECE, OR MASS SEPARATION IS ACHIEVED IN VARIOUS MANNERS, INCLUDING THE USE OF SCREENS..., AND MAGNETIC SEPARATORS FOR FERROUS WORKPIECES IN NONFERROUS MEDIA. SEPARATION CAN BE PERFORMED AT THE MACHINE WHILE REINTRODUCING THE MEDIA BACK INTO THE SYSTEM..., SEPARATION IS ALSO ACHIEVED BY TRANSFERRING PARTS AND MEDIA INTO A CONTAINER FOR SUBSEQUENT SEPARATION. --- TOUCH BLACK --- SCENE 15. CG, SUPER: Barrel/Rotary Tumbling tape 591, 07:27:05-07:27:08 barrel tumbling tape 591, 07:27:11-07:27:37 dissolve to same shot, barrel tumbling, zoom out BARREL, OR ROTARY, TUMBLING IS A LOW-PRESSURE PROCESS INVOLVING THE CONTROLLED SLIDING AND ROLLING ACTION OF WORKPIECES, MEDIA AND COMPOUND. AS THE BARREL ROTATES, THE LOAD MOVES UPWARD TO A TURNOVER POINT. GRAVITY OVERCOMES THE FORCES HOLDING THE MASS TOGETHER AND THEN THE UPPER LAYER

5 SLIDES DOWN TO THE BOTTOM OF THE BARREL. MOST ABRADING OCCURS DURING THE SLIDE. SCENE 16. tape 445, 12:29:25-12:29:32 parts loaded in to barrel tape 445, 12:29:57-12:30:15 dissolve to, barrel sealed and started CG, SUPER: Open-Ended Tilted & Open-Ended Bottle-Necked Octagonal Multi-Drum Multicompartment Submerged TUMBLING BARRELS CAN BE OPEN-ENDED, TILTED AND OPEN-ENDED, BOTTLE-NECKED, OR OF SEVERAL HORIZONTAL DESIGNS INCLUDING OCTAGONAL, MULTI- DRUM, MULTICOMPARTMENT, AND SUBMERGED. SCENE 17. tape 603, 13:11:36-13:11:44 barrel tumbling ROTATIONAL SPEEDS RANGE FROM 4 ROTATIONS PER MINUTE FOR LARGE BARRELS TO 60 ROTATIONS PER MINUTE FOR SMALL BARRELS. IDEALLY, BARREL SPEED SHOULD BE AS FAST AS POSSIBLE WITHOUT DAMAGING THE WORKPIECES. SCENE 18. tape 592, 08:02:54-08:01:10 pan, barrel tumbling PROCESSING TIME RANGES FROM MINUTES TO MANY HOURS, DEPENDING ON WORKLOAD, MEDIA, CUTTING-ACTION SEVERITY AND FINISHING RESULTS REQUIRED. SCENE 19. tape 591, 07:24:39-07:24:57 parts coming out of barrel tumbling, separated from media UPON COMPLETION OF THE FINISHING PROCESS, WORKPIECES AND MEDIA ARE USUALLY SEPARATED BY DUMPING BARREL CONTENTS ONTO VIBRATING SEPARATION SCREENS, OR BY DISCHARGING WORKPIECES AND MEDIA INTO A PAN FOR TRANSFER TO A SEPARATION MACHINE. --- TOUCH BLACK ---

6 SCENE 20. CG, SUPER: Centrifugal Disk Finishing tape 587, 04:05:05-04:05:15 centrifugal disk finishing CENTRIFUGAL DISK FINISHING IS A HIGH-ENERGY MASS- FINISHING PROCESS. SCENE 21. tape 587, 04:14:58-04:15:18 centrifugal disk finishing from above showing rotating disk base CENTRIFUGAL DISK FINISHING MACHINES CONSIST OF AN OPEN-TOP BOWL WITH STATIONARY SIDEWALLS AND A ROTATING DISK BASE. SCENE 22. tape 587, 04:10:43-04:10:59 centrifugal disk finishing starting tape 587, 04:12:35-04:12:52 dissolve to, c.u. pan from workpieces and media in center if tub to workpieces and media at side walls of tub AS THE DISK ROTATES AT PERIPHERAL SPEEDS AS FAST AS 2000 FEET OR 700 METERS PER MINUTE, MEDIA, COMPOUND AND WORKPIECES IN THE CONTAINER ACCELERATE OUTWARD. ON CONTACTING THE SIDEWALLS, WHICH SERVE AS A BRAKE, THE WORKLOAD DECELERATES AS IT IS FORCED UPWARD BY THE MASS BEHIND IT. MEDIA AND WORKPIECES RISE TO THE TOP OF THE LOAD, FLOW TOWARD THE CENTER OF THE CONTAINER AND THEN DOWN TOWARD THE DISK. SCENE 23. tape 588, 05:11:15-05:11:54 centrifugal disk finishing beginning BECAUSE OF THE HIGH CENTRIFUGAL FORCE PRESSING THE MEDIA AGAINST THE WORKPIECES, PROCESSING TIME IS REDUCED TO ONE-HALF TO ONE-TENTH THAT OF VIBRATORY FINISHING, WITH SIMILAR OR LOWER MEDIA COST. WITH VARIABLE-SPEED EQUIPMENT, HEAVY DEBURRING AND EDGE RADIUSING CAN OFTEN BE COMBINED WITH MORE GENTLE FINE-FINISHING OPERATIONS. SCENE 24. tape 587, 04:07:36-04:08:02 centrifugal disk finishing being

7 manually attended to HOWEVER, THE PROCESS CANNOT ACCOMMODATE AS WIDE A VARIETY OF PARTS AS OTHER FINISHING PROCESSES. --- TOUCH BLACK --- SCENE 25. CG, SUPER: Centrifugal Barrel Finishing tape 591, 07:04:30-07:04:40 centrifugal barrel finishing CENTRIFUGAL BARREL FINISHING, LIKE CENTRIFUGAL DISK FINISHING, IS A HIGH-ENERGY MASS-FINISHING PROCESS. SCENE 26. tape 591, 07:01:42-07:01:54 zoom out, centrifugal barrel finishing machine with doors open CENTRIFUGAL BARREL FINISHING MACHINES HAVE TWO OR MORE DRUMS, OR WORKLOAD CONTAINERS, THAT MOUNT ON THE PERIPHERY OF A TURRET. SCENE 27. tape 591, 07:02:06-07:02:30 parts loaded in drum THESE DRUMS ARE TYPICALLY FILLED WITH PARTS, MEDIA, COMPOUND AND WATER TO 60 TO 80 PERCENT OF CAPACITY. SCENE 28. tape 591, 07:05:21-07:05:26 drum loaded to turret tape 591, 07:05:35-07:06:00 dissolve, machine being turned on ONCE FILLED, THE DRUMS ARE LOADED ON TO THE TURRET..., AND THE MACHINE TURNED ON. SCENE 29. tape 591, 07:08:07-07:08:18 dissolve, c.u. pan of centrifugal barrel finishing AS THE TURRET ROTATES IN ONE DIRECTION, THE DRUMS ROTATE IN THE OPPOSITE DIRECTION. THE RESULTING CENTRIFUGAL FORCE IS CONSIDERABLY GREATER THAN THAT GENERATED BY DISK MACHINES, PROVIDING 20 TO 50 TIMES FASTER PROCESSING THAN VIBRATORY FINISHING.

8 SCENE 30. tape 591, 07:12:12-07:12:32 workpieces being washed after centrifugal barrel finishing THE PROCESS MAINTAINS SMOOTH RUBBING ACTION WITHOUT WORKPIECE IMPINGEMENT. THUS, FINE FINISHES CAN BE OBTAINED ON PRECISION AND FRAGILE WORKPIECES. ALSO, HIGH COMPRESSIVE STRESSES CAN BE IMPARTED FOR STRESS RELIEF, AND SMALL MEDIA CAN BE USED FOR UNIFORMLY FINISHING EDGES AND RADII. --- TOUCH BLACK --- SCENE 31. CG, SUPER: Spindle Finishing tape 602, 01:03:23-01:03:32 spindle finishing tape 591, 07:23:14-07:23:25 spindle finishing SPINDLE FINISHING IS A LOOSE-ABRASIVE PROCESS THAT USES THE SAME GENERAL MEDIA AS OTHER MASS- FINISHING PROCESSES. UNLIKE THEM, HOWEVER, IT IS LIMITED TO PROCESSING ONLY ONE OR A FEW PARTS AT A TIME. SCENE 32. tape 602, 01:06:05-01:06:25 media in tub, spindle immersed in the media and rotated spindle finishing TYPICALLY, THE MEDIA IS HELD IN A ROUND TUB THAT MAY ROTATE. ONE OR MORE SPINDLES, WHICH HOLD ONE OR MORE WORKPIECES, ARE IMMERSED IN THE MEDIA AND ROTATED. SPINDLES GENERALLY ROTATE AT 10 TO 3000 ROTATIONS PER MINUTE. SCENE 33. tape 602, 01:06:43-01:06:59 dissolve to, c.u. spindles coming out of spindle finishing THE PROCESS RESULTS IN EXTREMELY RAPID AND PRECISE DEBURRING AND SMOOTH FINISHES. SCENE 34. tape 591, 07:21:48-07:22:03 parts being loaded in to spindle finishing machine ONE DRAWBACK OF SPINDLE FINISHING IS THE REPETITIVE LOADING AND UNLOADING OF WORKPIECES,

9 WHICH INCREASES LABOR NEEDS OR NECESSITATES AUTOMATION. --- FADE TO BLACK ---