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EP2915628B1 - Procédé et système pour finissage vibratoire de parties de composite stratifié - Google Patents

Procédé et système pour finissage vibratoire de parties de composite stratifié Download PDF

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Publication number
EP2915628B1
EP2915628B1 EP15156158.6A EP15156158A EP2915628B1 EP 2915628 B1 EP2915628 B1 EP 2915628B1 EP 15156158 A EP15156158 A EP 15156158A EP 2915628 B1 EP2915628 B1 EP 2915628B1
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EP
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Prior art keywords
vibratory
particles
media
trough
accordance
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EP15156158.6A
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German (de)
English (en)
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EP2915628A1 (fr
Inventor
Brian K. Hovik
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Boeing Co
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Boeing Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B31/00—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor
    • B24B31/06—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor involving oscillating or vibrating containers

Definitions

  • Deburr manufactured parts In a variety of manufacturing processes, it is desirable to deburr manufactured parts after they have been machined or subjected to other processing steps. Parts that have been produced by casting, machining, laminating and other fabrication techniques frequently have burrs and surface roughness that are not considered acceptable in the final product. Finishing of such an article can include the removal of burrs and modification of the surface finish. Deburring is the general term given to various processes for rounding or smoothing the edges of parts and removing burrs from them, in order to provide a part with the desired finish characteristics.
  • the finishing medium can include particles having relatively sharp points or corners, which can work their way into grooves and crevices of the article, thereby smoothing the article and removing burrs and sharp edges.
  • the finishing medium can have a cleaning or surface polishing effect.
  • the vibratory deburring process produces a slightly sanded looking surface.
  • the present disclosure is directed toward one or more of the above issues.
  • the present disclosure provides a method for vibratory finishing of a composite laminate according to appended claim 1. Further embodiments are defined by the appended dependent claims.
  • mass finishing or "vibratory finishing” is a mechanical and/or chemical process that is applied to finish component parts. Vibratory finishing processes can remove burrs and smooth the surfaces of mass-produced articles.
  • vibratory deburring reduces manual labor and can provide more consistent results than manual deburring, it has primarily been applied only to metal parts.
  • manufacturers of vibratory finishing equipment acknowledge that metal parts are the major field of application for this technology, and that mass finishing technologies are also used for wood, rubber, stone and plastic.
  • vibratory finishing is not believed to have been applied to laminated composite parts.
  • typical vibratory finishing media is not compatible with composite materials.
  • composite laminated parts tend to "float" atop vibratory media, and do not naturally immerse themselves in the media.
  • vibratory finishing machines that are commercially available operate at a fixed frequency and magnitude of vibration that is not suitable to finishing laminated composite parts.
  • known vibratory finishing systems and methods not only teach away from finishing laminated composite parts, but teach away from systems that are adjustable in a way that they could be made suitable for finishing laminated composite parts.
  • a system and method have been developed for applying vibratory deburring processes to laminated composite parts.
  • This process utilizes automated vibratory deburring machines with specific deburring media, specific RPM and processing times to deburr these parts, which eliminates the need for manual single-part deburring of many composite parts. This saves time, money and eliminates many ergonomic issues that can arise with manual deburring. Preliminary testing with certain media has shown excellent results that meet exacting specifications.
  • FIGs. 1 and 2 Shown in FIGs. 1 and 2 is a trough-type vibratory finishing apparatus 100, such as are commercially available from Rosler America, of Battle Creek Michigan and other manufacturers.
  • Another commercially available vibratory finishing machine that has been used in this type of process is the model SVP-5 made by Hammond Roto Finish of Kalamazoo Michigan.
  • the vibratory finishing machine 100 includes a large tub or trough 102 that receives finishing media, indicated generally at 104, and the article to be treated 106.
  • the trough 102 is supported on springs 108 and is attached to a motor 110 that drives a drive shaft 112 that is positioned below the trough 102.
  • the drive shaft 112 is attached to the spring-mounted trough 102 with bearings 114 and is provided with offset or off-center counterweights 116, so that the drive shaft 112 vibrates as it rotates, and thus transmits this vibration through the bearings 114 to the trough 102.
  • This configuration causes the trough 102 to vibrate at a frequency that depends on the rotational speed of the drive shaft 112, and a magnitude that depends on the weight and offset position (i.e. how much the counterweights are off-center) of the counterweights 116.
  • rotation and vibration of the drive shaft 112 causes the trough 102 to vibrate in a generally elliptical motion, as indicated by arrow 118.
  • This vibration of the trough 102 causes the individual particles (136 in FIGs. 4A, 4B ) of the finishing media 104 and the part(s) 106 that are being finished to rotate individually within the trough 102 in a small circular motion, as indicated by arrows 120, and the whole mass of the media 104 to rotate or churn in a "rolling" motion simultaneously in one direction about a horizontal axis, as indicated by arrows 122.
  • vibratory finishing machines of the general type shown in FIGs. 1 and 2 have typically had a fixed vibrational speed. Indeed, it does not appear that vibratory finishing machines of this type having an adjustable speed are commercially available at all, and those that are commercially available all operate at a speed of 2100 RPM. Unfortunately, vibratory finishing machines of this type that operate at that speed are largely ineffective with composite materials, for reasons discussed above.
  • the vibratory finishing system depicted herein is compatible with composite materials, and its operational parameters, specifically the vibrational frequency and magnitude of vibration, have been developed and optimized for them.
  • the vibratory finishing machine 100 includes both a motor RPM controller 124 and a tachometer 126 to allow a user to adjust and verify the RPM of the motor 110, which determines the vibrational frequency.
  • This speed adjustment mechanism allows a user to change the RPM to find an optimum RPM for the parts 106 that are to be finished, whether composite parts or other types of parts. This not only allows a user to find a suitable speed for finishing composite parts, but can also allow a single vibratory finishing machine to be selectively adjusted for use with metal parts, composite parts, and other types of parts, if desired.
  • a motor frequency of around 2700 RPM with the offset counterweights 116 provided on the drive shaft 112, will vibrate the trough at a frequency in the range of 40-50 Hz, such as a specific frequency of 45 Hz. Frequencies in this range have been found to be effective for composite materials, while the typical 35 Hz frequency of prior vibratory finishing machines is not.
  • the vibratory finishing machine 100 can be configured to allow for the addition or subtraction of counterweights 116 to allow a user to create a desired offset so that the vibration has a desired magnitude (combined with the selected RPM).
  • the frequency of vibration is a function of the rotational speed of the drive shaft 112
  • the magnitude of vibration is a function of the mass of the counterweights 116 in relation to the combined mass of the trough 102, vibratory media 104 and part(s) 106. These latter characteristics are, in turn, affected by the size and volume of the trough 102.
  • a Hammond SVP-5 vibratory finishing machine was modified according to the present disclosure and used to finish composite parts.
  • the modified machine included a trough having a volume of 0.14 cubic metres (5 cubic feet), and was modified to run at 2700 RPM, as discussed above.
  • This machine included four, 2kg (41 ⁇ 2 pound) counterweights 116. These weights were each increased by 0.7kg (11 ⁇ 2 pounds), providing four 2.7kg (6-pound) counterweights (10.9kg or 24 pounds total) positioned eccentrically on the drive shaft, as shown in FIG. 2 . Imposing this additional weight on the weighting mechanism helped provide a satisfactory magnitude for the deburring motion with the lighter weight deburring media.
  • FIG. 3 A close-up view of the trough 102 loaded with finishing media 104 and having parts 106 being finished therein is provided in FIG. 3 .
  • the finishing media 104 Under the vibrating motion of the trough 102, the finishing media 104 is agitated in the trough 102, and tends to behave almost like a liquid.
  • the part 106 that is immersed in the finishing media 104 gradually rolls and tumbles within the media, as particles of the finishing medium repeatedly contact its edges and surfaces, gradually removing burrs and smoothing rough edges and surfaces, and also rounding edges of the part.
  • the vibratory finishing machine 100 also includes one or more water inlets 128, which provide a flow of process water to the volume of abrasive media 104.
  • the process water sometimes with a small amount of mild liquid soap (e.g. 30:1 water to soap ratio), is slowly metered into the media 104 to provide liquidity, some lubricity, and washing action to wash away and remove the media swarf and abraded particles of substrate.
  • the trough 102 includes an outlet or drain 130 at its lower extremity and drain conduit 132, which allows the process water to drain away. Strainers, filters, etc. (not shown) can be placed in or associated with the drain conduit 132 to remove the media swarf and particles of substrate that are washed away by the process water.
  • the machine 100 can be configured to deposit these particles into a waste tub (not shown) before the waste water is discharged.
  • the system for adding the process water and the associated waste tub can be standard components that are commonly included with commercially available vibratory finishing systems.
  • an individual trough 102 can be provided with dividers 134, so that multiple parts 106 can be simultaneously finished in separate portions of a single trough 102.
  • a divider 134 is also shown in the trough 102 of the finishing machine 100 in FIG. 1 .
  • multiple parts 106 can be simultaneously placed in a single or undivided portion or region of a vibratory finishing trough 102, and finished together.
  • the finishing media 104 comprises individual abrasive particles 136.
  • Perspective views of individual finishing media particles 136 which can be used in a deburring process in accordance with the present disclosure, are shown in FIGs. 4A and 4B .
  • the finishing media 104 can include particles 136 having various shapes and sizes.
  • the particles 136a shown in FIG. 4A have a tetrahedral shape
  • the particles 136b shown in FIG. 4B have a conical shape.
  • Other shapes can also be used.
  • These particles 136 can range in size from about 6.35mm (1 ⁇ 4") to about 63.5mm (21 ⁇ 2”) in their maximum dimension. Other sizes can also be used.
  • the particles 136 can have relatively sharp points or corners 138, which tend to work their way into grooves and crevices of the part 106 that is being finished, thereby smoothing the article and removing burrs and sharp edges on the outer part surface.
  • the particles 136 of finishing media 104 are made of two parts: an abrasive and a binder.
  • the abrasive includes titanium oxide
  • the binder is synthetic acrylic.
  • the media is about 10%-20% titanium oxide, held in a binder of synthetic urea-resin that constitutes 80%-90% of the volume of the particle 104.
  • Vibratory finishing media having this general formulation is commercially available under the product designation SY from Vibra-Finish Co. of Los Angeles, California, for example.
  • the specific gravity of the finishing media be from about 1.5 to 2.0, so that the sectional density of the total volume of the particles 136 is approximately equal to the sectional density of the composite laminate parts 106 that are to be finished.
  • This aspect of the vibratory finishing media 104 allows the composite part 106 to naturally "sink” in the media, rather than “float” atop it, thus allowing the part to become substantially immersed in the media.
  • This media formulation is different than the standard media commonly used for finishing metal and other parts. Specifically, many vibratory finishing media formulations use aluminum oxide as an abrasive, which is generally incompatible with composite materials. On the other hand, it has been found that titanium oxide abrasive works well with composite parts. However, it is believed that the suitability of this type of abrasive media for composite materials has not previously been known. Additionally, the binder, being a synthetic, does not require any processing compound (e.g. soap) for the finishing process. Instead, the processing fluid can be ordinary water, leaving the parts soap-free, receiving only a water rinse and towel dry at the end of the process.
  • processing compound e.g. soap
  • the abrasive particles 136 of the media 104 are of a generally constant make-up throughout their volume, such that as each particle 136 gradually wears down with use, its surface retains the same abrasive quality, even as it changes shape and size. That is, during use, the surface of the abrasive particles 136 will gradually wear away, exposing the underlying material, which has substantially the same abrasive quality and characteristics. In this way, the abrasive particles 136 retain their operational characteristics as they gradually wear down during use, until they are of a size where it is considered desirable to replace them with new, full sized particles. Replacing the worn particles 136 can be effectively accomplished by adding new particles 136 periodically, so as to maintain a given percentage of larger full-sized particles.
  • FIG. 5 Shown in FIG. 5 is a partial sectional view of an end portion 202 of a composite part 200. Prior to deburring, the end 202 of the part 200 includes sharp edges 204. After vibratory finishing in accordance with the present disclosure, the sharp edges 204 are smoothed to a rounded profile 206. The degree of edge break or edge relief that is desired will vary from one situation to another.
  • an edge break or round-over of about 0.13mm (0.005") can be provided on the exposed edges of a composite part. It will be apparent that the magnitude of the edge break will depend at least in part on the length of vibratory processing and the grit level of the abrasive media 104.
  • a logic flowchart outlining the steps in an embodiment of a method 500 for deburring and finishing laminated composite parts in accordance with the present disclosure is provided in FIG. 6 .
  • the trough of the vibratory machine is filled with finishing media particles (step 502). It is considered desirable to fill the trough no more than about 80% full, but not less than about 50% full, by volume.
  • the process water flow is turned on (step 504).
  • the process water can be ordinary water, without any additives, such as soap or the like.
  • the process water washes debris out of the volume of finishing media particles, enhancing the finishing process by removing residue that has been worn off of the part, and removing abrasive dust that has been worn off of the finishing media particles.
  • the process water flow that is used in this process is about double the amount of flow water that is typically used in vibratory finishing of metal parts.
  • a process water flow of 0.013 to 0.019 litres per second per cubic metre (0.35-0.50 gallons per hour per cubic foot) of volume of finishing media can be used.
  • a process water flow of 0.002 litres per second (2 gallons per hour) has been used.
  • the machine can be started (step 506) - that is, the vibration can be initiated at the desired frequency.
  • the parts to be deburred can be placed into the trough of the finishing machine (step 508), with the parts being immersed in the finishing media. It has been found desirable that the volume of parts placed into the trough not exceed about 10% of the total trough volume, in order to avoid damage from the parts contacting each other, and/or to avoid the parts being inadequately finished.
  • the parts are then left in the vibrating trough for a set time (step 510), while the process goes forward. In one embodiment, it has been found that parts can be processed for about 60 minutes with good results. In general, it is believed that vibratory finishing for about 45-60 minutes is likely to be sufficient. Those of skill in the art will be able to determine optimal settings for any given part and media combination to provide the desired edge-break and surface treatment.
  • the finished parts can be removed from the machine (step 512).
  • parts can be removed from the trough while the machine is running, which can help to speed up the batch processing flow.
  • the machine and the process water flow can be shut off (step 514) either before or after removal of the parts.
  • the parts can be rinsed with fresh water (step 516) and dried, making them ready for use.
  • the entire composite laminate part will show signs of deburring, which leaves a slightly dull, sanded appearance on the part, and is especially noticeable on the "tool-side" of the parts (i.e., the side of the composite part that was held against a form or "tool” while being cured).
  • the finishing media particles 136 gradually wear away with use. Consequently, it is desirable to periodically refresh the vibratory media (step 518) by removing particles below a certain lower threshold size and replacing the removed particles with a comparable volume of new particles, so that the particle size distribution is kept within a desired range. This can be done by dumping all of the particles from the trough into a vibratory sieve mechanism (not shown), which sorts out all particles below a certain size, depending on the size of sieve that is used, thus removing the smallest particles.
  • the remaining particles which are greater in size than the sieve that was used, can be returned to the trough for continued use, and a volume of new particles (or particles of suitable size) can be placed into the trough to bring the particle volume back up to a desired "full” level (step 502).
  • refreshing of the vibratory media particles involves removing particles below about 12.7mm (1 ⁇ 2") in size, and replacing them with a comparable volume of particles of 25.4mm (1") to 63.5mm (21 ⁇ 2") size.
  • the apparatus and method provides for the automated batch processing of composite parts, removing burrs occurring on the outer part surface.
  • the use of automated finishing allows for batching of many parts, eliminates the human-error of over-burring, and reduces or eliminates the possibility of ergonomic issues that are often associated with manual deburring, such as carpal-tunnel syndrome.
  • the process disclosed herein has the potential to save a tremendous amount of time and money by providing a much more cost effective and safe way to deburr the large number of composite parts that are and will be made. Labor cost will be highly reduced by transferring the labor-intensive manual deburring to automated equipment.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
  • Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)

Claims (10)

  1. Procédé pour une finition vibratoire d'une pièce stratifiée composite, comprenant :
    placer des particules (136) d'un milieu vibratoire (104) dans une cuve (102) d'une machine de finition vibratoire (100) ;
    placer une pièce composite stratifiée (106) dans la cuve de telle sorte que la pièce composite stratifiée soit sensiblement immergée dans le milieu vibratoire ;
    le procédé étant caractérisé en ce que les particules du milieu vibratoire comprennent un abrasif d'oxyde de titane dans un liant synthétique, et
    le procédé comprend en outre le fonctionnement de la machine de finition vibratoire à une fréquence de vibration de 40 Hz à 50 Hz avec le milieu vibratoire et la pièce composite stratifiée disposés dans la cuve.
  2. Procédé selon la revendication 1, dans lequel le liant du milieu vibratoire comprend de l'acrylique synthétique.
  3. Procédé selon la revendication 1, dans lequel les particules du milieu vibratoire ont une taille dans la plage d'environ 6,35 mm (1/4") à environ 63,5 mm (2 ½") dans leur dimension maximale.
  4. Procédé selon la revendication 1, dans lequel un volume total des particules du milieu vibratoire dans la cuve a une densité en coupe sensiblement égale à une densité en coupe de la partie stratifiée composite.
  5. Procédé selon la revendication 1, dans lequel les particules du milieu vibratoire comprennent environ 10 % à 20 % en volume d'abrasif d'oxyde de titane dans un liant de résine d'urée synthétique.
  6. Procédé selon la revendication 1, comprenant en outre l'utilisation de la machine de finition vibratoire pendant une période de 45 à 60 minutes.
  7. Procédé selon la revendication 1, comprenant en outre l'application d'eau de traitement au milieu vibratoire à un débit d'environ 0,013 à 0,019 litre par seconde par mètre cube (0,35 à 0,50 gallon par heure par mètre cube) de volume du milieu vibratoire.
  8. Procédé selon la revendication 1, dans lequel le fonctionnement de la machine de finition vibratoire comprend la rotation d'un arbre d'entraînement (112), couplé à la cuve, l'arbre d'entraînement ayant des contrepoids décalés (116) qui amènent l'arbre d'entraînement à démontrer une rotation excentrique approximativement 10 % supérieure par rapport au diamètre de l'arbre d'entraînement.
  9. Procédé selon la revendication 1, comprenant en outre l'ajustement de la fréquence vibratoire de la machine de finition vibratoire.
  10. Procédé selon la revendication 1, comprenant en outre le rafraîchissement du milieu vibratoire en éliminant des particules usées d'une taille inférieure à environ 12,7 mm ½") dans leur dimension maximale et en remplaçant les particules usées par un volume de particules comparable d'une taille de 25,4 mm (1") à 63,5 mm (2½") dans leur dimension maximale.
EP15156158.6A 2014-03-07 2015-02-23 Procédé et système pour finissage vibratoire de parties de composite stratifié Active EP2915628B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US14/201,083 US20150251291A1 (en) 2014-03-07 2014-03-07 Method and system for vibratory finishing of composite laminate parts

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EP2915628A1 EP2915628A1 (fr) 2015-09-09
EP2915628B1 true EP2915628B1 (fr) 2017-11-15

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US (1) US20150251291A1 (fr)
EP (1) EP2915628B1 (fr)
JP (1) JP6449048B2 (fr)
CN (1) CN104889877B (fr)

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EP2915628A1 (fr) 2015-09-09
US20150251291A1 (en) 2015-09-10

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