IJSTE - International Journal of Science Technology & Engineering | Volume 4 | Issue 5 | November 2017 ISSN (online): 2349-784X
Investigation and Optimization of Process Parameters of Centrifugal Barrel Machine Deep S. Shukla Student Department of Mechanical Engineering C.U. Shah College of Engineering and Technology Wadhwan City
Vipul V. Jambukiya Student Department of Mechanical Engineering C.U. Shah College of Engineering and Technology Wadhwan City
Vishal A. Kanjariya Student Department of Mechanical Engineering C.U. Shah College of Engineering and Technology Wadhwan City
Anil N. Rathour Assistant Professor Department of Mechanical Engineering C.U. Shah College of Engineering and Technology Wadhwan City
Abstract Centrifugal barrel finishing (CBF), like other mass finishing processes, uses media, compound, and water to deburr and surface finish components. The difference between this and other processes is that centrifugal action results in a very fast, highly controllable operation. The process, sometimes called mass orbital barrel finishing, maintains a smooth rubbing action with little or no workpiece impingement, making it possible to produce fine finishes on precision and fragile parts. Our project objective to find out the optimum process parameter for the centrifugal barrel machine for the operation deburring and polishing. In our industry near about 80% products of company passed from the deburring and polishing operation. So that is important and necessary to find out the optimum parameter for deburring and polishing. For finding the optimum result we collect the process parameters from the industry for the deburring and polishing. Keywords: Deburring, Polishing, Centrifugal Barrel Machine, High Energy Mass Finishing, BFC-130, BFC-150 ________________________________________________________________________________________________________ I.
INTRODUCTION
Surface Preparation offers several different sizes and styles of high energy centrifugal barrel machines. Centrifugal barrel machines provide extremely intensive processing - generating a force on the mass of parts, media and compound of up to 30 times that of gravity. Centrifugal barrel machines often provide finishing results that simply cannot be achieved in a standard vibratory process. A centrifugal barrel machine is typically comprised of four barrels horizontally mounted between two main drive turrets. As the two main turrets rotate all barrels rotate in the opposite direction of the turret. The capacities of centrifugal barrel machines range from ½ cf to 12 cf of processing volume. This process requires manual loading and unloading as well as parts and media separation. Deburring is, to put it simply, a finishing method used in industrial settings and manufacturing environments. Metal is frequently machined using many processes in order to create pieces of specific shape and size, and it may be welded, molded, cast, trimmed, slit or sheared. These procedures often create ragged edges or protrusions. The raised particles and shavings that appear when metal blanks are machined are referred to as burrs, and the process by which they are removed is known as deburring. Metal must go through an extensive manufacturing process in order to be formed into a serviceable, efficient enclosure. Machining operations commonly employed include grinding, drilling, milling, engraving, and turning. These procedures may leave behind burrs, of which there are three types: Poisson, rollover, and breakout. Removing these unwanted imperfections is a process called deburring. Below table shows the machine specification used for this case study. We take valve plate, spring plate, washer of different sizes for the study. Model no Type Capacity No of barrel Motor rating RPM Loading of parts / media Unloading of parts / media Method of separation Approximately Weight
Table – 1 Machine Specification CHE-240-3B Semi-Automatic 240 ltr. 4 15 HP 0-125 RPM Manual Automated Vibratory separator 2200 kg
CHE-80-3B Semi-Automatic 80 ltr. 4 7.5 HP 0-150 RPM Manual Automated Vibratory separator
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Investigation and Optimization of Process Parameters of Centrifugal Barrel Machine (IJSTE/ Volume 4 / Issue 5 / 026)
Ceramic Media used in Centrifugal Barrel Machine: The ceramic media are abrasive stone used in metal finishing operation to impart the desire finish on the components the ceramic media are available in various shapes grades and size to suit each type of components. Plastic media and porcelain media are also part of our vast product range. Table – 2 Ceramic Composition Ceramic composition Component Silica Aluminum oxide Potassium oxide Sodium oxide Magnesium oxide Calcium oxide Iron oxide Titanium dioxide
Percentage 47-57 35-45 2-5 0.5-1 1-2 Ceramic used
Ø6 mm 6*12 mm
10*15mm
Fig. 1: Ceramic Media
Corn Cob: This is an agro product the material is absorbent, smooth flowing and is available in different grain size as per require applications the corn cob grains have high absorb resistance low specific gravity and are employed mainly for drying in the rotary driers and vibratory finishing machine, in addition they are also pretreated with some polishing agents and used for polishing in the centrifugal high energy finishing machines to impart extra high glows on the components. Barrel Finishing Compound (BFC): Almost all cast, stamped or machined metal components require some level of additional finishing, from simple smoothening, to precision dimensioning, to mirror-surfacing depending on their end use. The BFC series range include liquid and powder compounds for general use for all metals, as well liquid and powder compounds for specific metal and specific applications. The BFC series compounds have general application such as descaling, degreasing, cutting, deburring, radiusing, smoothening, burnishing, polishing and mirror finishing there by allowing all metals to be appropriately finished to make use of their natural tonality and luster.
Appearance Specific gravity Solubility in water General Flash point Ph. Content Application
Table – 3 BFC – 130 BFC-130 Physical and chemical characteristics Yellowish-green slightly viscous liquid with soapy odour. 1.050-1.055 Soluble Fire and Explosion Hazard Data Non-flammable / Non-explosive 93˚c 9.0-9.5 Liquid compound with extra rust inhibition properties. Main application ferrous , MS , sintered components
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Investigation and Optimization of Process Parameters of Centrifugal Barrel Machine (IJSTE/ Volume 4 / Issue 5 / 026)
II. DATA COLLECTION FROM CFM
Sr. No. Part Name Operation Material grade Cycle time (min.) RPM Weight / barrel Ceramic media spe. & Qty. Water (ltr.) Chemical description & volume Part oty ./ barrel Defects Recommendation
Sr. No. Part Name Operation Material grade Cycle time (min.) RPM Weight / barrel Ceramic media spe. & Qty. Water (ltr.) Chemical description & volume Part oty ./ barrel Defects Recommendation
Sr. No. Part Name Operation Material grade Cycle time (min.) RPM Weight / barrel Ceramic media spe. & Qty. Water (ltr.) Chemical description & volume Part oty ./ barrel sDefects Recommendation
Table – 4 Running Cycle 3 4 2229164VP 8906010VP Polishing Polishing C98 C98 45 45 85 85 60 60 45Kg 45Kg (Ø6mm, (Ø6mm, 6*8mm) 6*8mm) 12.5 12.6
1 8806040VP Polishing C98 55 90 60 45 Kg (Ø6mm, 6*8mm) 13.3
2 8211040VP Polishing C98 55 80 60 45Kg (Ø6mm, 6*8mm) 14.3
BFC 130
BFC 130
BFC 130
BFC 130
BFC 150
35 1
55 3 Low shining
6 0
13 0
27 1
Dark spot
5 CR105 SP Deburring S.S. 304 55 52 60
6 8228130 VP Deburring C98 45 45 60
45Kg (Ø6mm ,6*12MM)
45Kg (Ø6mm, 6*12MM)
13.6
14.57 CUTTING OIL 70 18 0
burrs Table – 5 Change in Cycle Time 3 4 2229164VP 8906010VP Polishing Polishing C98 C98 40 40 85 85 60 60 45Kg 45Kg (Ø6mm, (Ø6mm, 6*8mm) 6*8mm) 12.5 12.6
1 8806040VP Polishing C98 60 90 60 45 Kg (Ø6mm, 6*8mm) 13.3
2 8211040VP Polishing C98 60 80 60 45Kg (Ø6mm, 6*8mm) 14.3
BFC 130
BFC 130
BFC 130
BFC 130
BFC 150
35 0
55 1
6 0
13 0
27 1 Burr
Table – 6 Change in RPM of Barrel 3 4 2229164VP 8906010VP Polishing Polishing C98 C98 45 45 90 90 60 60 45Kg 45Kg (Ø6mm, (Ø6mm, 6*8mm) 6*8mm) 12.5 12.6
6 8228130 VP Deburring C98 40 45 60
45Kg (Ø6mm ,6*12MM)
45Kg (Ø6mm, 6*12MM)
13.6
14.57 CUTTING OIL 70 18 0
2 8211040VP Polishing C98 55 85 60 45Kg (Ø6mm, 6*8mm) 14.3
BFC 130
BFC 130
BFC 130
BFC 130
BFC 150
35 2
55 1 Low shining
6 0
13 2
27 0
bending
Line marks
CUTTING 70 17 2 Bending
5 CR105 SP Deburring S.S. 304 60 52 60
1 8806040VP Polishing C98 55 95 60 45 Kg (Ø6mm, 6*8mm) 13.3
7 351305 VP Deburring C98 45 45 60 45Kg (Ø6mm ,6*12MM) 14.51
5 CR105 SP Deburring S.S. 304 55 60 60
6 8228130 VP Deburring C98 45 53 60
45Kg (Ø6mm ,6*12MM)
45Kg (Ø6mm, 6*12MM)
13.6
14.57 CUTTING OIL 70 18 0
7 351305 VP Deburring C98 40 45 60 45Kg (Ø6mm ,6*12MM) 14.51 CUTTING 70 17 0
7 351305 VP Deburring C98 45 50 60 45Kg (Ø6mm ,6*12MM) 14.51 CUTTING 70 17 1 Dark spot
III. RESULT After collecting data from the industry, we get the optimum process parameter for the deburring and the polishing department. With the help of this data we can get the optimum result with minimum number of parts for redebuirring operation. For the best result we change the process parameters one by one. First we change the cycle time first time we increase cycle time and second All rights reserved by www.ijste.org
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Investigation and Optimization of Process Parameters of Centrifugal Barrel Machine (IJSTE/ Volume 4 / Issue 5 / 026)
time we decrease the cycle time both the time we observe the result. Secondly we change the barrel RPM first time we increase RPM and second time we decrease the RPM both the time we observe the result. Third first time we increase part quantity and second time we decrease the part quantity both the time we observe the result. By changing the process parameter this way, we find based on this data collection the optimum process parameter for the given component. Table – 7 Result Sr. No. Part Name Operation Material grade Cycle time (min.) RPM Weight / barrel Ceramic media spe. & Qty. Water (ltr.) Chemical description & volume Part oty ./ barrel
1 8806040VP Polishing C98 55 90 60 45Kg (Ø6mm, 6*8mm) 13.3
2 8211040VP Polishing C98 55 80 60 45Kg (Ø6mm ,6*8mm) 14.3
3 2229164VP Polishing C98 45 85 60
4 8906010VP Polishing C98 45 85 60
5 CR105 SP Deburring S.S. 304 55 52 60
6 8228130 VP Deburring C98 40 50 60
BFC 130 30
7 351305 VP Deburring C98 45 45 60 45 Kg (Ø6mm, 6*12mm) 14.51
45 Kg (Ø6mm, 6*8mm)
45Kg (Ø6mm ,6*8mm)
45 Kg (Ø6mm, 6*12mm)
45 Kg (Ø6mm, 6*12mm)
12.5
12.6
13.6
14.18
BFC130
BFC130
BFC 130
BFC150
BFC130
CUTTING OIL 70
48
6
13
28
11
17
REFERENCES [1] [2] [3] [4] [5] [6]
R&D progress in SRF surface preparation with centrifugal barrel polishing (CBP) for both Nb and Cu, A. D. Palczewski (2013) United States Patent, Ditscherlein, Jul. 25, 1989 Development of a metal removal model using spherical ceramic media in a centrifugal disk mass finishing machine, Vikram Cariapa(2007) centrifugal barrel polishing of L-band niobium cavities, T. Higuchi, (2001) centrifugal barrel polishing of cavities worldwide, C. Cooper, (2011) detailed surface analysis of incremental centrifugal barrel polishing (CBP) of single-crystal niobium samples, A. D. Palczewski, (2011)
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