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Forgings, Castings and Additive Manufactured Components Introduction Surface Finishing Applications we redefine Forgings, Castings and Additive Manufactured Components Introduction Why Choose Us? We’re the UK’s We’re a family run business that pride ourselves on working as a strong, unified team of specialists. leading experts in We believe in British Born in the United Kingdom, we are unique in our product design providing effective and the manufacture of our specialist machines and consumables. We’re here for you Being based in the heart of the country means we and efficient processes, have easy access to all of our clients. We have experience With five decades of experience and knowledge in and solutions, for the the finishing industry, we know what works for you. We provide options manufacturing industry. We have an impressive range of media and compounds to choose from, including one of the best polishing compounds in the market. We also provide a wide range of machinery and subcontract services to meet all of your needs. we redefine: We go the extra mile We’ll tailor our services to your needs, not the other Vibratory Finishing way round. Our service is all about you. High Energy Finishing Consumables Precision Polishing Subcontract Services 2 3 Mass Finishing What is Mass Finishing? Man x Machine x Media = M3 Mass finishing is a process that The aim of this process can vary based on the type of application, which include: Almost all manufactured components have automates the mechanical and experienced some surface improvement, high stock removal chemical finishing of various deburring to ensure that these are in an acceptable shaped parts. This is a stage in descaling condition for the end-user. the manufacturing process of removal of machining lines We understand the importance of surface finishing for additive manufactured parts, forgings and castings and have worked closely with major manufacturers in different industries to adapt and develop finishing solutions that meet their components, which allows large removal of surface defects stringent requirements. It has been proven that the solutions we’ve developed have benefited the industry by reducing processing times and producing a repeatable and quality product. numbers of parts to be finished radius formation simultaneously. super-finishing Surface Finishing is Critical in Keeping FEA Analysis Manufactured Components Repeatable. The processes can be configured as a batch system or a continuous system. Parts that are processed using a batch system Manufacturing companies usually implement mass finishing will be loaded into the machine, processed and unloaded before the next batch is ready. A continuous system is where the techniques in their processes for the economic advantages, and parts are loaded at one end, and come out at the other in the finished condition. the consistent results achieved. Manual finishing processes are known to be labour intensive, with the disadvantages of rework By combining our complete process knowledge with decades of experience, and our all-encompassing range of machinery, and high rejection rates, and inconsistent results. Having we can deliver the most optimum, cost-effective and environmentally friendly finishing solution for your needs. identified the issues, we offer a wide range of unique solutions that improve current processes, achieving the repeatability and quality desired by manufacturers. ActOn Research and Development We are continually evolving our processes and machines, making them more effective. We also have academic connections throughout the United Kingdom and around the world, who help facilitate our Research and Development department, where we house various metrological equipment to ensure that our customers’ requirements are met and Super Finish Tolerance exceeded. With projects involving modal and dynamic FEA analysis of our finishing machines, and the persistent gathering of empirical data on our various compounds, medias and machines, we ActOn Target Performance strive to design and optimise everything we do to a high standard. 4 5 Surface Finishing Surface Finishing of Surface Finishing of Additive Manufactured Forgings & Castings Parts Forging and casting are manufacturing processes used across various industries to transform metal materials Additive Manufacturing is a process of joining into a desired geometry. material layer upon layer, as opposed to subtractive Generally, forgings and castings tend to have a rough manufacturing techniques. The most common types of surface finish and a dull appearance. Manual finishing is time consuming and does not deliver consistent results. metal additive manufacturing are Laser Sintering and ActOn engineers recommend using vibratory finishing Electron Beam Welding. or high energy finishing machines to achieve a smooth surface and a polished finish. Over the years, we have developed and optimised processes on various forgings Metal parts that have been produced through additive In many cases, the results achieved via High Energy (HE) and castings with different finishing specifications, such manufacturing tend to have a textured surface with an Finishing cannot be achieved in a standard vibratory as the removal of surface defects and flash lines or average Roughness (Ra) of approximately 30 microns. process, particularly applications that include achieving achieving a surface finish of Ra 0.03 μm. The values of Ra may increase at support locations a high surface finish, a mirror finish and the removal of and may decrease depending on the geometry manufacturing defects. HE finishing can be 10 times profile. The base of components manufactured using faster than traditional finishing methods, and produces the aforementioned processes generally present a superior finishes. It is one of the most efficient batch The process benefits of considerably lower roughness. finishing methods. High Energy finishing is a process that automates the Components can be processed wet or dry. In a wet ActOn machinery and mechanical and chemical finishing of various shaped process, parts are generally loaded as a batch with media parts. This is a stage in the manufacturing process of and a solution made of a barrelling compound and water. consumables include: components that allows small or large numbers of When processing large or fragile components,divider parts to be finished simultaneously. plates may be fitted to form compartments within the 1. Significant reduction in roughness barrel so that parts may be processed individually, 2. Shorter processing time than traditional methods High Energy Machines are used to reduce surface ensuring no impingement. 3. Increased part cleanliness roughness, deburr and polish processed parts. The action 4. Removal of surface defects and flash lines of these machines relies on the high force and speed at 5. Corrosion protection which the media chips come in contact with the processed components. The forces can be as great as 15-20 times 6. Non-part specific the force of gravity, depending on the rotational speed 7. No major tooling required and the turret size of the centrifugal machine. 8. No requirement of fixturing 9. Consistent and repeatable results 6 7 Products Man x Machine x Media = M3 Products we redefine Here are just a handful of forgings, castings and additive manufactured products that we can help to perfect. Courtesy of the Manufacturing Technology Centre. 8 9 Process Applications Using both our Vibrota range and Centrifugal High Energy machines together with our bespoke media and Applications compounds, we’ll achieve a high standard finish. Component Output Required Machine Type Media Type Compound Type Typical Manufacturing Process Method Deburring Media Polishing Media Drying Media Deburring Polishing Time ABS Housing Smooth Finish 300 mins Additive Manufactured Ultem Plate Clean and Smooth Finish 120 mins Additive Manufactured Smooth Finish and Ra Value Titanium 3D Prototype 150 mins Additive Manufactured Between 2μm and 3μm Spoiler Smooth Finish 120 mins Additive Manufactured Improve Surface Finish Titanium Aerospace Prototype 300 mins Additive Manufactured From 19.2μm to 3.2 μm Titanium Bone Plate Mirror Finish 300 mins Additive Manufactured Improve Surface Finish Aluminium Latch Fitting 240 mins Casting From 6.1μm to 1.3 μm Brass Figurines Deburring and Bright Finish 60 mins Casting Zinc Handle Clean Prior to Plating 15 mins Casting Bronze Sculpture Deburring 300 mins Casting Steel Land Base Turbine Deburring 60 mins Casting Rocker Arm Remove Flash 10 mins Casting 120 mins Forging Piston Deburring and Bright Polished Finish 70 mins Forging Inconel Turbine Blade Surface Improvement and Polishing Brass Stamping Descaling, Removal of Graphite and Polishing 250 mins Forging Key Deburring, Cleaning and Polishing 30 mins Forging Femur Removal of Machining Lines 35 mins Forging Hip Joint Cleaning, Degreasing, Deburring and Mirror Finish 90 mins Forging 10 Parts can vary. This is a guideline only. If you require any other parts processing, please contact us. 11 Vibrota Range Bowls Troughs Duals Dryers Each of our Bowls are simple to operate and highly We offer Troughs in many different sizes and an infinite choice The orbital Dual finisher works to both deburr and Our unique, elliptical-shaped Vibratory bowl drying efficient, manufactured in classic designs and sizes of length and width combinations, making them one of our most dry in one single unit. This is both an excellent and machines suit a variety of finishing needs. Our to meet your unique applications. versatile. These are particularly useful
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