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An Investigation of the Surface Finishing Action and Resulting Surfaces Produced by the Cascade Finishing Process Peter Charles Brust Iowa State University

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An Investigation of the Surface Finishing Action and Resulting Surfaces Produced by the Cascade Finishing Process Peter Charles Brust Iowa State University Iowa State University Capstones, Theses and Retrospective Theses and Dissertations Dissertations 1997 An investigation of the surface finishing action and resulting surfaces produced by the Cascade Finishing process Peter Charles Brust Iowa State University Follow this and additional works at: https://lib.dr.iastate.edu/rtd Part of the Industrial Engineering Commons, and the Mechanical Engineering Commons Recommended Citation Brust, Peter Charles, "An investigation of the surface finishing action and resulting surfaces produced by the Cascade Finishing process " (1997). Retrospective Theses and Dissertations. 11777. https://lib.dr.iastate.edu/rtd/11777 This Dissertation is brought to you for free and open access by the Iowa State University Capstones, Theses and Dissertations at Iowa State University Digital Repository. It has been accepted for inclusion in Retrospective Theses and Dissertations by an authorized administrator of Iowa State University Digital Repository. For more information, please contact [email protected]. INFORMATION TO USERS This manuscript has been reproduced from the microfilm master. UME films the text directly from the original or copy submitted. Thus, some thesis and dissertation copies are in typewriter &ce, while others may be from ai^ type of computer printer. The quality of this reproduction is dependent upon the quality of the copy submitted. Broken or indistinct print, colored or poor quality illustrations and photographs, print bleedthrough, substandard margins, and improper alignment can adversely affect reproduction. In the unlikely event that the author did not send UMl a complete manuscript and there are missing pages, these will be noted. Also, if unauthorized copyright material had to be removed, a note will indicate the deletion. Oversize materials (e.g., m^s, drawings, charts) are reproduced by sectioning the original, beginning at the upper left-hand comer and continuing from left to right in equal sections with small overlaps. Each original is also photographed in one exposure and is included in reduced form at the back of the book. Photographs included in the original manuscript have been reproduced xerographically in this copy. Kgher quality 6" x 9" black and white photographic prints are available for any photographs or illustrations appearing in this copy for an additional charge. Contact UMI directly to order. UMI A Bell & Howell Infoimation Conq)ai^ 300 North Zed) Road, Ann Aibor MI 48106-1346 USA 313/761-4700 800/521-0600 An investigation of the surface finishing action and resulting surfaces produced by the Cascade Finishing process by Peter Charles Brust A dissertation submitted to the graduate faculty in partial fulfillment of the requirements for the degree of DOCTOR OF PHILOSOPHY Major; Industrial Engineering Major Professor: Ralph F. Scrutton Iowa State University Ames, Iowa 1997 UMI Number: 9737691 UMI Microfonn 9737691 Copyright 1997, by UMI Company. All rights reserved. This microform edition is protected against unauthorized copying under Title 17, United States Code. UMI 300 North Zeeb Road Ann Arbor, MI 48103 ii Graduate College Iowa State University This is to certify that the Doctoral dissertation of Peter Charles Brust has met the dissertation requirements of Iowa State University Signature was redacted for privacy. Major Professor Signature was redacted for privacy. For the Major Program Signature was redacted for privacy. For the Graduate College iii TABLE OF CONTENTS INTRODUCTION I 1. AN OVERVIEW OF THE CASCADE PROCESS AND RELATED FINISHING TECHNIQUES 4 n. EXPERIMENTAL PROCEDURE 23 in. EXPERIMENTAL RESULTS 42 IV. DISCUSSION OF RESULTS AND CONCLUSIONS 119 V. SUMMARY AND FUTURE RESEARCH 135 APPENDIX A. FIXTURE AND SPECIMEN DRAWINGS 141 APPENDIX B. DATA FOR SCREENING EXPERIMENTS 144 APPENDIX C. DATA FOR EXPERIMENT ONE 150 APPENDIX D. DATA FOR EXPERIMENT TWO 160 APPENDIX E. DATA FOR EXPERIMENT THREE 170 APPENDIX F. DATA FOR EXPERIMENT FOUR 177 APPENDIX G. DATA FOR EXPERIMENTS FIVE, SIX, SEVEN 182 iv APPENDIX H. DATA FOR EXPERIMENTS EIGHT, NINE 189 REFERENCES 194 V ACKNOWLEDGMENTS The author would like to thank the U.S. Department of Education and the Iowa State University IMSE Department for the support they provided while he was a Fellow of Concurrent Manufacturing. Fellow students, IMSE faculty and staff and committee members are also thanked for their camaraderie, assistance and guidance. A very special thanks goes to my Major Professor, Dr. Ralph F. Scrutton, for his tutelage and Great Patiencel 1 INTRODUCTION The objective of this research was to perform a systematic study of the Cascade Finishing™ process with respect to its ability to improve surface finish. The Cascade Process (CP) is currently only being used to clean and deburr castings and machined parts and, as with most "mass" finishing processes, the process produces consistent results but is not well understood at the fundamental level. Despite the fact that several major manufacturing firms, e.g. John Deere, Eaton and GM, are currently using the Cascade Process there has not as yet been any published work on the subject of the process except for a single trade journal article. No objective data has been gathered on the process effects and a fundamental study of how CP actually works has never been completed. In addition, the selection of the process operating parameters is currently based upon operator experience and/or very limited empirical data. Likewise, the fixtures are designed by trial and error. While these fixtures are inexpensive the time and effort required to develop them limits the flexibility of the process. In order to provide a more thorough understanding of the CP this research focused on the following areas: 1. Determining the surface textures produced by the process. This included not only taking standard roughness measurements such R, and R^, but profile tracings, material ratio curves and micro-photographs of the surfaces produced. This characterization of the surface finish was performed to ascertain the effects of CP on surfaces and to provide a means of comparing the surfaces with those produced by other "mass" finishing methods and manufacturing processes, e.g. shot peening. 2. Determining the significance and effects of three key machine operating parameters; run time, vibratory firequency and fixture clearances. This included building empirical models to aid the proper selection of process 2 parameters and determining the repeatability of CP with respect to surface finishing. 3. Determining the effects of media type, size and geometry on the surface finish produced. Four different media were investigated; an abrasive triangle, steel pins and two sizes of steel balls. The steel media which were studied are frequently used in CP standard deburring operations and their inclusion in the study was to help determine what surface finish changes occur when the process is used for deburring. 4. Determining the effects of surface orientation vis a vis the flow of the media, direction of vibrations, and the fixture walls. This was studied to aid in the design of fixtures and to see if selected surfaces could be shielded from the surface finishing action of CP. 5. Determining the effects of the initial surface finish with respect to run time, vibratory frequency and post CP surface finish. 6. Providing a cursory study of the effects of CP on the micro-hardness, stock losses and the imparted compressive residual stresses of the surfaces. This was done to aid users of the CP in the understanding of any possible changes in the surface integrity of parts that occur during processing. 7. Collecting other pertinent process information such as peak accelerations and media flow rates and developing an understanding on how the process actually works. It is hoped that this research not only provides important information to engineers employing or considering employing the CP to deburr or improve surface finishes, but also provides insights into the process that will allow for the improvement of the machines and their operations. 3 The following dissertation is divided into five sections. After an overview of CP and related finishing processes, the experimental set ups and procedures are briefly explained with a short listing of the different experiments provided as a quick reference. The pertinent results of these experiments are then presented in part three, with much of the data and analysis placed in the Appendix. The next section discusses the experimental results and presents conclusions and a general explanation of the process. The need for future research and a summary make up the final section. Appendices, containing statistical analyses, fixture and specimen drawings, graphs, experimental designs, etc., and a list of references are also included. 4 I AN OVERVIEW OF THE CASCADE PROCESS AND RELATED FINISHING TECHNIQUES The Cascade Finishing Process Introduction The Cascade Finishing™ process (CP) is a proprietary finishing process developed by Iowa Engineered Processes Corp. (lEPC) of Independence, Iowa. The process uses a combination of burnishing, shearing and peening actions to deburr, clean internal and external surfaces, produce controlled edge radii and burnish a wide variety of metal parts. When abrasive media is used, a grinding action removes material and produces smooth, matte surfaces. The parts to be processed, ranging from .5 to 250+ kg (1.1 to 550 lbs), are set in a fixture that resides in the work chamber. A flow of media (usually case hardened steel) and a liquid
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