MACHINE - REPORT
VIBRATORY FINISHING MACHINE
A PROJECT REPORT SUBMITTED
IN PARTIAL FULFILLMENT OF THE REQUIREMENTS
FOR THE AWARD OF DEGREE OF
BACHELOR OF TECHNOLOGY
In
Mechanical Engineering
SUBMITTED BY
SUBMITTED TO
I/We, Name of the candidate, Roll Number, hereby declare that the work which is
being presented in the project entitled, “Title of the project” in partial fulfillment of
requirement for the award of degree of B.Tech. (ME) and submitted in the Department of
Mechanical Engineering, Ambala College of Engineering and Applied Research,
Ambala, Kurukshetra University, Kurukshetra, is an authentic record of my/our own
work carried by me under the supervision of Supervisor Name (Designation, Mechanical
Department, Ambala College of Engineering and Applied Research, Ambala).The matter
presented in this project Report has not been submitted in this or any other University /
Institute for the award of B.Tech Degree.
(Gourav Sachdeva)
2311662
(Name)
Roll Number
(Name)
Roll Number
(Name)
Roll Number
Department of Mechanical Engineering
CERTIFICATE
Certified that this project report entitled “TITLE OF THE PROJECT” is the bonafide
Ambala”, who carried out the project work under my supervision during August, 2016 -
November, 2016.
The Project work is an important aspect in the field of engineering, where contribution is
made by many persons and organizations. The present shape of this work has come forth
after contribution from different spheres.
REFERENCES 59-60
Note 1: The number of Chapters is just indicative. There may be more number of
Chapters in the Project but the format of the index has to be followed as given
above.
Note 2: Page numbering should be as per the given format i.e. pages from
candidates’ declaration to list of abbreviations should be in Roman and page
numbering of the Chapters should be in decimal numbers. The title pages of the
project report should NOT be numbered.
LIST OF TABLES
8|Page
LIST OF FIGURES
9|Page
Introduction
Mechanical surface finishing, also known as mass finishing or vibratory finishing, is a surface finishing
technology that has been around for more than six decades. At the time it was invented in the 1940s, mechanical
surface finishing revolutionized whole industries with regard to their surface finishing methods. Large
international companies like Volkswagen and Mercedes-Benz in Germany were literally queuing up to initially
get a hold of rotary barrels and, later on, the first mass finishing vibrators. Delivery times of 24 months or more
were not unusual.
Deburring previously was a purely manual operation with extremely high personnel costs, poor quality, and no
consistency or repeatability of results. Then, all of a sudden, manual finishing operations could be replaced with
a mechanical process that significantly reduced personnel costs but, more importantly, one that consistently
produced higher-quality parts with a high degree of repeatable results
• Grinding and polishing of medical implants, such as artificial knees, hips, ankles, etc. In the medical implant
industry, special mass finishing processes have been replacing robotic grinding and buffing systems (Fig. 1).
• Superfinishing of automotive gears down to a surface roughness of <2 (0.05 μm) to increase the life of power
trains, reduce running noise and, at times of high fuel cost, reduce the weight of these components without
jeopardizing their reliability (Fig. 2).
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• Surface finishing of aero-engine components, such as turbine blades, blisks, turbine disks, vanes, etc. In
combination with shot peening, mass finishing processes reduce the “maximum exhaust gas temperature”
(MEGT) and increase the time intervals between engine overhauls. Better surface finishing of turbine blades
also increases the acceleration and compression of the air mass flow in turbines, resulting in lower fuel
consumption—an invaluabletechnical benefit with today’s high cost of kerosene (Fig. 3).
Mass finishing media are generally classified into the following categories:
• Steel media (in hardened carbon steel and stainless steel) • Organic media (for example, granules made from
corn cob and walnut shells)
• Other media (for example, glass beads, polyamide micro-beads, etc.), which play only a minor role in
vibratory finishing and are not discussed further.
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The most commonly used mass finishing media are either ceramic- or plastic based. They account for
approximately 80–90% of all media used in mass finishing applications. All other media are specialties that are
used for certain applications, 14 Ceramic and plastic media always have one common characteristic:
Whereas in the case of ceramic media the carrier is clay, in the case of plastic media the carrier is either
polyester or urea resin. The most common abrasives used in ceramic and plastic media are:
• Silica (sand)
• Silicon carbide
• Zirconium
Depending on the application, mesh sizes can vary between 40 and 400.
The different types of media, how they are made, and for what applications they are generally used, are
subsequently described.
CERAMIC MEDIA
Applications: Due to their relative high density, ceramic media are generally used for aggressive grinding on
“tough” metals, such as steel, stainless steel, titanium, and so on.
However, certain ceramic media can also be used for fine grinding—producing low Ra values on the part
surface.
Porcelain media, made from pure alumina, can be used for polishing, producing a high-gloss surface.
Limitations: Ceramic media can chip, and chips may lodge in bore holes and undercuts.
PLASTIC MEDIA
Density: 60–85 lbs/ft3
Production method: Abrasive/liquid resin mix is poured into molds at room temperature; mix hardens within
15–20 minutes.
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Available shapes: triangle, tri-star, double wedge, cone, pyramids of different shapes, parabolic. Applications:
Due to their somewhat lower density, plastic media are generally used on softer metals, such as aluminum, zinc,
and brass.
STEEL MEDIA
Density: 210–250 lbs/ft3 (depending on size)
Material: hardened carbon steel, standard carbon steel, stainless steel. Production method: Cut to length from
wire/round bar and then forged.
Available shapes: Sphere (ball), satellite, oval, anglecut cylinder, etc. 15 Figure 11: Ceramic media Figure 12:
Plastic media Figure 13: Steel media
Applications: Pressure deburring of steel parts, ball burnishing (or ball polishing) of mainly stainless steel parts,
occasionally also aluminum parts.
ORGANIC MEDIA
Material: Mostly corn cob or walnut shell granules.
Applications: For drying of parts after vibratory finishing. Also used for highgloss polishing of metal parts,
mainly stainless steel, aluminum, titanium, etc., in combination with a mixed-in polishing paste.
SELECTION CRITERIA:
MEDIA SHAPE, SIZE, AND ABRASIVE CONTENT
Media shape, size, and abrasive content are crucial for achieving the optimum surface finish.
MEDIA SHAPE
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The geometry of the parts to be finished generally determines the shape of the media to be used. A simple rule
of thumb is:
Round and compact media :Use for standard applications. There is less danger of media lodging in the part;
lower danger of chipping (in the case of ceramic media); and lower wear rate. Typical shapes include: cylinder,
cone, ball.
Media with sharp edges: For parts with complex geometry and difficult-to-reach surfaces. Danger of chipping;
higher wear rate. Typical shapes include: tri-star, triangle, arrowhead.
MEDIA SIZE
Small media size: Produces a smoother surface by having more contact with the part surface; usually requires
longer processing times and more gentle processing.
Large media size: Faster removal of burs and radiusing of sharp edges on the parts; produces a rougher surface
than small media; more aggressive grinding required.
ABRASIVE TYPE
Silica: For deburring/deflashing of relatively soft metals, such as aluminum, brass, and zinc.
Silicon carbide: For aggressive grinding on difficult-to-machine metals. This abrasive produces dark surfaces.
Aluminum oxide: Characteristics are similar to silicon carbide.
Zirconium: Used in plastic media for adding weight. Mainly used for fine grinding of all kinds of metals.
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Vibratory machinery and deburring equipment for deburring, surface finishing, burnishing, washing, cleaning,
pre-plate finishing, polishing and drying
Vibratory Compounds & media for use with ceramic, porcelain, copper, steel, plastic and other such parts.
MECHANISMS OF CLEANING :
The removal of objectionable contaminants from metallic surfaces can be accomplished by mechanical
processes, chemical processes, or a combination of both.
Mechanical Processes
1. The physical removal of surface layers by means of aggressive mechanical action. Shot blasting with glass,
aluminum oxide, sand, or dry ice (CO2 ) pellets. Mass finishing via vibratory mill or part-on-part burnishing.
Grinding. Abrasive pad buffing.
2. The physical removal of surface contaminants with minimal base metal removal. Gas scrubbing by
electrocleaning, cathodically, anodically, or periodic reverse. Impingement by high- or low-pressure spray. 68
Turbulence, such as that supplied by slosh washers or turbo washers, in which cleaning solution is turbulently
flowed over the surfaces to be cleaned. Cavitation supplied by ultrasonics. Abrasive brushing in solution.
Abrasive slurry.
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Mass Finishing
This method helps with off-line capabilities. Cleaning, deburring, descaling, and burnishing are surface
improvements accomplished by mass finishing. The base metal is conditioned prior to additional surface
finishing. Critical areas are rounded out and burnishing can result in low rms value or high luster. The process
combines mechanical energy and chemical action. The mechanical contribution is by tumbling in horizontal or
oblique barrels or by using vibratory bowls. Specially blended chemicals are added in dilute-liquid form or low-
concentration powders. They wet and react with the surface of parts, allowing other parts or special media (e.g.,
plastic, ceramic, or stone) to work on the parts. Mass finishing is especially helpful to seal porosity of aluminum
and zinc before transfer to the plating line. If parts are to be mass finished or if this is a feasible option, trial
evaluations are recommended to determine best suited equipment, media, and optimum: media-to-parts ratio,
flow rates, and cycle times.
A tumbler is a rotating drum, which rolls the parts against each other like a cement mixer. The parts can be
burnished either wet or dry using a plastic or ceramic media with an abrasive or a polishing compound.
Selecting the desired combination of these effects will produce a variety of different burnishing possibilities.
The parts can generally be taken right off the process line, without drying, and loaded directly into the tumbler.
Vibratory finishers operate in a similar manner but use a vibrating bowl rather than a rotating drum. As
mentioned the vibratory bowls can also be charged with different types of media and compounds to achieve the
type of contrast desired. Both the tumbler and vibratory mill will produce a nondirectional pattern on the part
surface and cannot really reproduce the effect achieved by a hand-buffing operation; however, they operate at
much lower cost and can be preprogrammed to produce the identical result batch after batch. Consequently, they
are less dependent on the human factor for consistent quality. For certain parts compromising on quality a bit in
order to control the cost allows the manufacturer to sell the finished piece at the desired price point and still
make a profit.
PROTECTIVE TOPCOATS
After coloring and highlighting are completed the part is ready to be topcoated to protect it from corrosion. Even
though the parts may look completely finished the decorative antique finish is quite susceptible to corrosion or
tarnish unless protected. The products most often used to accomplish this are clear lacquers. As in all the
previous operations there can be many options open to the finisher, depending on the durability required of the
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final finish, operating cost, equipment cost, environmental concerns, etc. In actual practice there are a few
options that provide the most benefits.
Air-Dry Lacquers
These products can be water-based or solvent-based and commonly utilize acrylic or urethane polymers to form
a protective film. The acrylics are the lower cost option and can provide an effective topcoat for many parts
used indoors only, such as light fixtures, wall sconces, etc., that do not see heavy wear. Generally, solvent-based
lacquers are more protective than water-based products but also present a potential solvent fume problem in
terms of discharge into the atmosphere.
Baking or Cross-Linkable
Resins These products are widely used on parts that require high wear resistance and/or outdoor exposure and
include polyurethanes, epoxies, and nitrocellulose lacquers—all of which can cross link during drying to form a
very dense and tenacious film. Very often they are cured in an oven at 250 to 350°F for 10 to 20 minutes to
speed drying. These products are suitable for high-value parts or surfaces that must be exposed to outdoor
weathering elements. It is also possible to use lacquers containing corrosion inhibitors that specifically protect
copper alloys. The most widely used is benzotriazole and its related compounds. These materials can be blended
into many types of lacquers in small concentrations and provide an extra measure of corrosion resistance,
making them particularly well suited for use on items such as marine hardware, building components, etc.
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Some parts do not require a permanent antique finish but are designed to allow the surface to age naturally in
service. For example brass hand rails, building fascia panels, elevator panels, and other parts can be initially
sealed with a temporary protective film such as paste wax or oil. When installed they will be handled during
normal use and constantly “burnished” by this contact. Over time they will develop a natural, soft patina that
will ultimately be permanent because it is being constantly developed.
1. Mild alkaline soak clean: 8-10 oz/gal mix; 150°F; 4-6 minute soak with air agitation.
4. Mild acid tarnish remover: 10% sulfuric acid; room temperature; 1-3 minutes.
1. Heavy-duty alkaline soak clean: 10-12 oz/gal mix; 170-180°F; 4-6 minute soak.
2. Alkaline electroclean; 12 oz/gal of high caustic formula, 160°F; 6-12 V anodic current; 100-150 A/ft2 ; 2-4
minutes.
11. Sour rinse (to neutralize cyanide); 2% sulfuric acid; room temperature; 30 seconds.
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12. Rinse: clean tap water; 20 seconds.
1. Deburr: vibratory finishing machine using ceramic media and deburring compound.
4. Rinse: 20 seconds.
5. Rinse: 20 seconds.
7. Rinse: 20 seconds.
18. Lacquer.
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19. Bake cure
WASTE TREATMENT
This area is of critical importance to the metal-finishing industry because a chemical process line cannot operate
without proper treatment of waste products, as mandated by the Federal EPA and appropriate state or local
agencies. Since these process lines utilize a variety of different chemical products it is impossible to offer a
simple overview of the waste treatment picture. A few comments are in order, however, about the types of
wastes generated in these lines and the waste treatment methods commonly employed to achieve compliance
with the regulations.
Acid Residues Acid solutions quickly dissolve metals from the parts being processed and, like the alkaline
chemicals, respond well to simple neutralization techniques to precipitate the metal content. Acid and alkaline
rinsewaters are typically mixed together for treatment and help to neutralize each other.
Cyanide Residues
The rinses following the brass plating bath will contain cyanide, copper, and zinc. This rinsewater is typically
subjected to a cyanide destruct process, which oxidizes and decomposes the cyanide to harmless chemicals and
also precipitates the copper and zinc content. The metallic sludge is then collected on filters and disposed of as
hazardous solid waste.
Solid Waste
The waste treatment methods above generate hazardous solid waste in the form of metal-bearing precipitate,
which is commonly collected on a particle filter cartridge or plate filter element. This solid waste can be sent out
to a licensed waste treater for proper stabilization and landfilling.
Dragout Rinses These are often used as preliminary rinses following a heated process tank such as a heated
cleaning tank or plating tank. Dragout rinses are perhaps the single most effective and least costly way to
minimize chemicals in the drain. They are typically followed by a treated rinse, which is fed to ion exchange or
other treatment. For process solutions carrying only a moderate level of metals, a single dragout rinse is
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sufficient. A brass plating tank, on the other hand, will contain fairly high concentrations of cyanide, which is
costly to treat. Consequently, it is common to see two or three dragout rinses used to minimize the level of
cyanide sent to waste treatment.
Mechanical/Mass Finishing
Mechanical surface finishing, also known as mass finishing or vibratory finishing, is a surface finishing
technology that has been around for more than six decades. At the time it was invented in the 1940s, mechanical
surface finishing revolutionized whole industries with regard to their surface finishing methods. Large
international companies like Volkswagen and Mercedes-Benz in Germany were literally queuing up to initially
get a hold of rotary barrels and, later on, the first mass finishing vibrators. Delivery times of 24 months or more
were not unusual.
Deburring previously was a purely manual operation with extremely high personnel costs, poor quality, and no
consistency or repeatability of results. Then, all of a sudden, manual finishing operations could be replaced with
a mechanical process that significantly reduced personnel costs but, more importantly, one that consistently
produced higher-quality parts with a high degree of repeatable results.
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Advantages Of Using A Vibratory Finishing Machine
In many industries, vibratory finishers are the most commonly used piece of mass finishing equipment. Used to
remove burrs and smooth surfaces, vibratory finishing machines come in countless shapes and sizes but, at their
core, work the same way: they spiral and vibrate parts within a media to achieve a desired level of finish. That
isn’t to say, however, that all vibratory finishers are created equal. In this post, we’re going to discuss five of the
major advantages that you stand to gain by purchasing your vibratory finishing machine from CLM Vibetech.
1. Variable sizes
Available in sizes ranging from 1 to 100 cubic feet, our vibratory finishers can fit into any floorplan and any
production process.
2. Unparalleled versatility
A range of options, from automation of all or some of the functions of the machine to screen deck options that
allow for work to be done to your parts as they exit the machine, means that your vibratory finishing machine
can be utilized for several purposes across multiple applications.
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3. Heavy-duty construction
With an all heavy-duty, interlocking weldments and thick premium polyurethane linings, you can be confident
that the mass finishing equipment from CLM Vibetech is built to stand up to even the harshest processes.
Utilizing only premium and readily available components (bearings, seals, motors, and electrical components),
our finishing equipment is easy to service and maintain. As a result, you’ll experience a reduction in downtime
and an increase in productive, profitable hours.
No matter what you need, our vibratory finishing machines can get it done. With optional pneumatic gates,
compound systems, waste water treatment systems, rinse bars, step-down screens, noise covers, rust inhibit
stations and many more, your finisher can be tailored to your specific application.
Smoothing: improving the surface finish and blending of any defects or sharp edges
Pre-plate finishing: producing a flat, smooth surface finish prior to subsequent plating or coating;
Ball burnishing: high-intensity processing, normally within stainless steel balls, to produce a bright lustre finish
Barrelling or Tumbling: the original process for deburring or polishing components using a rotary drum rather
than a vibratory vessel
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Conclusion
Less wear on your component making them more durable and increasing power output
A smoother surface makes your component run cooler, faster and longer
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References
Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2003), Materials and Processes in Manufacturing (9th ed.),
Wiley, ISBN 0-471-65653-4.
Categories:
Industrial processes
Metalworking
Kohser, Ronald A. (2003), Materials and Processes in Manufacturing
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