When 3D printing (originally SLS) was invented in 1984 the concept attracted interest from designers and innovators alike. It was futuristic and unique and the notion fertilized considerations of what many uses “printing” could have however, the technology was young and limitations were apparent. It would be two decades and many R&D hours later before it would be available for on-demand manufacturing. This happened in 2006.
Since the first on-demand printers were put to use, most applications were limited to creating prototype models used as references and demonstrations of parts that would be made using traditional manufacturing techniques. The continuous developments have grown concepts and potential uses into the production of usable, functioning parts. It is now 2019 and the capabilities of part printing are seen in a range of materials and applications found in industries from automotive and aerospace to everyday consumer goods, but one issue still limits further advancement of the 3D printing industry’s almost limitless potential; Stair stepping. Stepping is a common issue, a result of printing a part from the bottom up, adding material layer by layer. With intricate parts with varying geometries, some layers are wider than others, creating a “stair” like step from one layer to the next. Although this issue is constantly being improved resulting in tighter tolerances, the fine steps on the finished parts surface still exist and can create both aesthetic and functionality issues.
A large portion of our business at Vibra Finish Ltd in Mississauga is surface improvement of parts manufactured using many different methods. We not only process parts in-house, we also manufacture the equipment to do the job and develop processes with special media and compounds that our customers can use in their facilities with our equipment. Recently we have seen a significant number of requests for this requirement, specifically from customers who have purchased 3D printers to make their own parts as well as manufacturers who make the printers themselves. Most of the materials used to make these parts are more resistant to traditional vibratory finishing. This was apparent during our early testing on these parts which we began a few years ago. To directly compare our results we processed two similar parts made from the same materials that are common in printing such as nylon, plastic, stainless steel, aluminum, and nitinol. For the test we used one part that was 3D printed, the other was machined or casted. The printed parts showed a significantly less wear rate than those made using other methods which meant in order to attain the same level of finishing; it required more consumption of water and medias as well as longer processing times. There are media on the market that have higher abrasives which reduce cycle times but the trade-off is the rate of wear in medias which can be significant.
Since these discoveries we have run thousands of parts for customers with varying requirements of printed parts. Our successes have come from our R&D department who have been working alongside our media suppliers developing new media of different shapes and sizes to accommodate different part geometries. These new 3D specific medias also contain a high level of abrasive, similar to “fast-cutting” media with bond compositions that are dense to combat the wear levels that take place when running extended cycle times. These new products along with our application specific, custom-built machines have opened up the gates where final-finish processing, done often by hand had previously bottle-necked the production volume.
The history of media finishing goes back centuries, long before sophisticated machinery would do the job for us. The concept is basic but the need for the application’s improvements are in high demand. With the manufacturing industry ever changing, it will continue to grow as the technologies of our time force us forward. You print the parts, we will finish things up. It’s what we do.
Zach B. McGillivray Business Development/R&D Manager Vibra Finish Ltd
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Vibratory Peening
Kumar Balan explores the efficacy of vibratory peening, its financial viability and its potential market reach. His article will cover all these aspects courtesy of data provided by Vibra Finish.
In the winter 2018 issue of The Shot Peener, we discussed two non-conventional peening techniques; one of which was Vibratory Peening. In addition to the superior surface finish, we learnt that the layer of compression was deeper with vibratory peening when compared to conventional shot peening. The process itself was significantly different from conventional peening in terms of media life, dust generation and utility costs. We concluded that this technique of generating residual compressive stress was worth further exploration. The results are discussed here.
Vibra Finish, a company based in Mississauga, Ontario (Canada) has conducted multiple studies to validate the established facts and clearly define limitations of this peening process. They have attempted to identify components, both industrial and domestic, that demand and could benefit from a combination of fatigue resistance and superior surface finish, both in a single step process.
When reviewing a new process, especially one that simulates an established technique albeit with marked improvements, skepticism is common. Such doubts include the technical efficacy of the process, financial viability and its potential market reach. Our discussion will cover all these aspects courtesy of data provided by Vibra Finish. Given that Vibra Finish operates conventional shot peening machines as well, our discussion is enriched by the comparison of both techniques under identical process variables.
Background
Vibratory finishing is a primary process in its own right and sometimes it is a supplementary process used to polish a shot-peened surface. As a secondary operation, it can eliminate surface roughness created during peening. Surface roughness, greater than a certain application dependent value, can have a detrimental effect on the fatigue life of the component. As we know, most specifications limit material removal in post-peening finishing to 10% of the ‘A” intensity value. Vibratory finishing could be controlled to stay well within this tolerance. Vibratory finishing is also used for deburring, burnishing, descaling and is ideal for finishing parts prior to painting, plating, heat treating, anodizing or simply to achieve an excellent final finish.
Vibratory finishing is categorized as a “mass-finishing” process, and when designed properly, will result in a batch of parts that is treated with uniformity and consistency. The process is not reliant on operator skill unlike certain other techniques such as buffing, filing, belting, etc. Instead, a batch of parts are loaded in bulk into a tub or continuously fed to a vibratory machine for inline operation. The tub is filled with finishing media and suitable compound(s) that when combined act as thousands of small filing surfaces scrubbing the parts. The compound assists the cleaning/finishing action of the media (usually made from ceramic). The choice of compound will depend on the material to be treated, the desired surface finish, and the individual application and process requirements. Additives in the compound could serve other purposes such as alkaline cleaning, acidic burnishing, washing and rust inhibition.
Just like any other process, vibratory finishing has controllable variables that alter the finish quality. Two of the main factors include the amplitude and frequency of vibration. Given the advantages of this process, it is a natural progression that vibratory finishing be extended in its application range to provide a peened and finished product in a single step.
Past Research
In 2016-17, Dr. Hongyan Miao and Prof. Martin Levesque from Polytechnique Montreal studied the fatigue life improvements of a certain alloy type using conventional peening and shot peening. The results from this test were encouraging enough to carry out further testing. The details of their testing are as follows:
Conventional shot peening was carried out in an Automated air type machine with a V2″ diameter nozzle propelling Z425 ceramic bead on the component. The target intensity was 8A, achieved at an air pressure of 20 PSI and media flow of 10 lb./minute. The part was fixtured on a rotary table.
Vibratory peening (this term is used to signify the sole purpose of this operation-peening) was performed in a batch-type tub filled with AISI Type 1018 Carbon Steel balls with diameters 1/8″, 3/16″ and Vi”, adding up to almost a ton in weight. The target intensity remained unchanged from 8A as in the conventional peening machine.
It is interesting to note the mix of media sizes in this process as compared to conventional shot peening where the reliance is on consistent media size, to the extent of using classifier screens to maintain the same in the machine. Due to proprietary nature of this process, further elaborations on the use of multiple media sizes is not readily available. A reasonable explanation would be to consider the mechanism of media movement in a batch-type tub, and the interaction of one size with another much like on a pool table. This is compared to conventional peening where a steady stream of media impacts the target.
Both media types (ceramic and carbon steel balls) were of comparable hardness in the range of 60 HRC.
In contrast to conventional shot peening where the part spinning on the table was targeted by the abrasive, the part in the vibratory tub was positioned 10″ below the ball bed surface with constant contact of the carbon steel balls.
The team plotted saturation curves using data sets obtained from both peening techniques and, with their distinct process parameters, they arrived at an intensity of 8.3A and 8.6A with shot peening and vibratory peening respectively. Residual stress measurements carried out on the test parts using X-ray diffraction displayed some interesting results. Shot peening produced a larger surface and maximum compressive residual stress (-212 MPa and -297 MPA respectively), as compared to -148 MPa and -225 MPa produced with vibratory peening. However, the difference was in the depth of compression. Vibratory peening produced -50 MPa at 520 micron below the surface whereas with shot peening, the same magnitude of residual stress, -50 MPa, went only 340 micron deep into the surface. In practical terms, if we are able to alter the process parameters in vibratory peening so that it generates the same magnitude of compressive stress as shot peening, we can expect this stress to stretch over a greater depth than with shot peening.
The surface roughness results were as expected. The study compared the surface roughness of the sample part as machined, shot peened and after vibratory peening. Roughness was tested on three samples, on three individual locations and the trend was the same in all cases. One such set of results is documented below for brevity.
Fatigue tests performed as part of this study generated similar average fatigue lives for both processes. However, they did find that the values from shot peening had significantly less standard deviation (minimal variation). The study concluded that rather than comparing similar Almen intensity values, future studies should compare the fatigue life measures for similar residual stress profiles, at different levels of roughness. Ultimately, the measure of all such processes is based on the extent to which fatigue life has been impacted, preferably in the positive direction.
Commercial Components and Vibratory Peening
Encouraged by the results of the previous tests, Vibra Finish continued with comparative tests on more conventional components – a turbine blade and an automotive transmission gear. The tests were to study the following:
Compare the effects of shot peening and vibratory peening on (a) open and (b) relatively closed geometries in order to learn the limitations presented by certain part types to this process.
Surface roughness
Residual stress and nature of curves (relieving of compressive stress as measured into the depth of the part)
The conventional shot peening process was carried out in an automated airblast machine under the following process parameters: Target intensity: 10 to 12A and 100% coverage. This was achieved using SI 10 regular hardness steel shot propelled at 30 PSI by a Vi” diameter nozzle at a stand-off distance of 8″ for a time cycle of 30 seconds.
Vibratory peening was carried out using single size, 3 mm diameter steel balls, in a batch type tub for a total cycle time of 10 minutes. Two sets of data, one for surface roughness and the other for residual stress (using X-Ray Diffraction) were analyzed.
Surface Roughness Data:
The surface finish results show an interesting trend in a relatively closed geometry component (gear) when compared with the blade with wide, open surfaces. The root section of the gear, which is the area of maximum stress concentration, is the most important region for measurement. In this region, the shot peened component exhibited a much rougher surface finish when compared to an identical vibra-peened component. All other regions of the gear such as the drive face, coast face and tip showed comparable surface roughness values in both processes. Geometry of the gear tooth, media access and media size could all be factors that might have contributed to the final roughness value in vibratory peening.
Though S110 was ideally suited to peen the smallest radius of the gear tooth without causing coverage issues, the surface roughness ended up much higher than with vibratory peening. However, we have to consider the fact that in order to achieve the same intensity (8 to 12A), the S-110 would’ve had to penetrate deeper than the 3 mm balls in vibratory peening, resulting in a rough surface profile.
A study of the residual stress profile provided further insight into the characteristics of both processes to induce compression in the parts.
Gear
The residual stress curve for this component is different from the classic “J” hook curve that was expected before the results were obtained. Also, this is a carburized component that may not necessarily show high values of residual stress when shot peened with SI 10 size media to a relatively lower intensity range (8 to 12 A). Though the residual stress at the surface of the shot peened sample is greater than that achieved with vibratory peening, the dissipation (or loss) of residual stress towards the depth of the material is much more controlled with the vibratory peened sample. Vibratory peening did record a seemingly anomalous reading when measured at 0.0008″ depth, registering a steep 33% drop from -79 ksi to -53 ksi before continuing with a controlled and gradual decline at deeper levels into the sample.
An obvious question that remains to be evaluated is whether the surface finish (roughness) was the cause of this steep drop in residual stress in the shot peened sample, especially considering the smoother surface after vibratory peening. The gear being carburized might have also led to the relatively lower magnitude of residual stress using both types of peening techniques.
Blade
A blade from a turbine wheel was chosen for its open geometry. As it turned out, the resultant residual stress followed the all-familiar J-hook pattern. Surprisingly, the compressive stress generated at the surface was greater with vibratory peening when compared to the shot peened sample. Once again, the open geometry of the part and material properties (softer than the gear) likely caused this result. An interesting observation is to be made at 0.0021″ depth where both processes register the maximum compression. Assuming the shot-peened part had developed a rough profile after peening, if one were to polish it by 10% of the ‘A” intensity value, i.e., 0.0011″, we will end up with a higher residual stress value (about -140 ksi) at the surface of the shot peened part. At this depth, the vibra-peened part will have a residual stress of-113 ksi without the need to be polished.
The drop in residual stress when going deeper into the component was drastic with the shot-peened part and followed a gradual decline with the vibra-peened component. This is a positive attribute of the latter process.
In both cases, it appears that the geometry of the part played a big role in generating increased magnitude of residual stress.
Conclusions and Future Steps
Vibratory peening certainly shows a lot of promise in terms of combining the two essential features in surface finish— smooth profile and compressive stress—in a single step. Moreover, in both examples, it has shown a gradual and smooth dissipation of this stress as one travels deeper into the material, demonstrating the controllability of the process. The next steps are to study the operating cost of both processes to assess the financial viability of the process. Vibratory peening does not possess the same consumable pattern that we are all familiar in conventional shot peening. This is also true in terms of capital costs involved in procuring a conventional shot peening machine.
Vibratory peening has yet not been governed by a specification. This might be the next step to increase the adoption of this process in known sectors. Meanwhile, a whole range of consumer parts could greatly benefit from this combined process.
About Vibra Finish
Vibra Finish, located in Mississauga, Ontario, Canada, offers a full range of vibratory finishing services and equipment. Their services include deburring, burnishing, descaling, vibrapeening, polishing, rust removal, cleaning, drying, corrosion protection, and peening services. Visit: vibra.com for more information.
A common deburring machine used for mass-finishing parts is a vibratory deburring machine, or vibratory tumbler, which utilizes abrasive tumbling media to deburr, clean, or polish unfinished or dirty parts or objects. At Vibra Finish, the abrasive media and unfinished or dirty parts are put inside a large drum. The drum vibrates, driving down the contents in a circular motion, mixing everything together. The unfinished or dirty parts are subsequently deburred, cleaned, or polished by friction with the abrasive material.
The kind of deburring, cleaning, or polishing desired and the part characteristics will determine the type, size, and shape of the abrasive media used. Some common types of tumbling media are abrasive steel, ceramic, organic materials, and plastic. These materials can be purchased in a variety of shapes such as cylinders, cones, stars, pyramids, wedges, spheres, ovals, and other forms, depending on the function needed. Openings in the parts will determine the size and shape of the media used. To prevent media lodging in the part, it should be a minimum of 70 per cent of the size of the hole or slot. This avoids two pieces getting stuck side by side in the piece.
Here are some common uses for abrasive media in the Vibra Finish process:
Steel Media – Use for heavy deburring, or shining, polishing, and burnishing metal, plastic, or ceramic parts. Since plastics have a high abrasion resistance, resulting in a matte finish after deburring, a second, polishing step is often required.
Ceramic Media – Use for light and heavy deburring and when fast deburring is needed. Good for hard, heavy metals (such as steel or stainless) and to remove rust on parts. Use for general-purpose polishing. Plastic, steel, stainless, and aluminum parts are often polished using ceramic media. Use ball shapes to polish aluminum to avoid nicks.
Plastic Media – Use for general metal deburring, precision deburring, polishing, and burnishing. Use on softer metals such as aluminum or brass and on threaded parts.
Organic Media (Walnut Shells, Corn Cob) – Use walnut shells for medium-to-light deburring. For light finishing and polishing, use walnut shells and corn cob meal. To clean and dry wet or dirty parts, use organic media. Corn cob is particularly desirable in finishing some metal parts because of its ability to absorb surface oils on the parts. Utilizing organic media is advantageous because they are natural, safer for the environment, biodegradable, durable, and reusable.
Wet tumbling compounds – Used by mixing with solid media to deburr, finish and polish parts, their function is to clean, enhance deburring, and for corrosion and rust protection.
Abrasive media for deburring equipment wears down slowly, but will vary on how aggressive the media is. Also, the smaller the media, the better the finish, but the longer it will take. The larger the media, the faster it will deburr. Having the correct media and the deburring machine full of parts is the key to successful finishing.
Vibra Finish has mastered every aspect of the metal-finishing process – including cleaning, polishing, smoothing, and deburring – making it Ontario’s go-to source for industrial finishing. But the company’s services also extend to selling a variety of media, compounds, and other materials to help customers with their private finishing applications. The Vibra Finish inventory includes 13 types of Vibra-Glo compounds for various applications, from burnishing to rust removal.
Cleaning, Smoothing, and Polishing Surfaces
Vibra-Glo compounds play an important role in the finishing process. Users throw these finishing compounds together into a system with water and media, and the machine’s sliding or tumbling action causes the compounds to clean, polish, and smooth the surfaces of the metal parts.
Wet compounds are available from Vibra Finish. They typically come in a paste form or are used with water in wet finishing processes. In addition, these compounds are formulated with properties that are tailored specifically for use in either tumbling barrels or vibratory systems.
Vibratory compounds are designed for finishing in vibratory machines, which are usually relied upon for thorough cleaning and deburring of delicate parts or parts with bores or recess that are difficult to reach. These compounds are also well suited to large surfaces. Adding a vibratory compound, along with selected media, to a vibratory machine that contains parts for mass finishing causes the machine’s rubbing action to have an abrasive effect on the parts, helping to clean them more effectively. Another benefit of compounds is their suspension properties, which stop the debris that arises from depositing back on the parts, thereby keeping the abrasive action constant.
The lineup of Vibra-Glo compounds available includes five types of rust inhibitors, two alkaline cleaners, two all-purpose cleaners, two mild acidic burnishers, and one type each of powdered concentrate and washing compound. The range that Vibra Finish carries is ample evidence of the many ways compounds benefit the finishing process.
Trust Vibra Finish compounds for a better finishing job every time.
