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Mass finishing is a group of manufacturing processes that allow large quantities of parts to be
simultaneously finished. The goal of this type of finishing is to burnish, deburr, clean, radius,
de-flash, descale, remove rust, polish, brighten, surface harden, prepare parts for further
finishing, or break off die cast runners. The two main types of mass finishing are tumble
finishing, also known as barrel finishing, and vibratory finishing.[1] Both involve the use of a
cyclical action to create grinding contact between surfaces. Sometimes the workpieces are
finished against each other; however, usually a finishing medium is used. Mass finishing can
be performed dry or wet; wet processes have liquid lubricants, cleaners, or abrasives, while
dry processes do not. Cycle times can be as short as 10 minutes for nonferrous workpieces or
as long as 2 hours for hardened steel.[1]
Mass finishing processes can be configured as either batch systems, in which batches of
workpieces are added, run, and removed before the next batch is run, or as continuous
systems, in which the workpieces enter at one end and leave at the other end in the finished
state. They may also be sequenced, which involves running the workpieces through multiple
different mass finishing processes; usually, the finish becomes progressively finer. Due to the
random action of the processes, mass finishing is as much an art as it is a science.[2]
Contents
Types
Tumble finishing
Vibratory finishing
Media
Functions of Media
Types of Media
Compounds
References
Notes
Bibliography
Types
Tumble finishing
Vibratory finishing
Media
Functions of Media
Media are designed for four things:
Cut
Media which cut can remove burrs and can smooth surfaces. As a carrier of abrasive grain, the
large medium pieces effectively increase the impact force of the abrasive on the metal part to
be cut, thereby improving the efficiency of the abrasive. Cutting media develop dull, matte
surfaces.
Luster
Some grades of medium are designed to promote luster on the surface of metal parts. These
products are generally non-abrasive or have a very low degree of abrasiveness. They deburr by
peening, rather than actually removing the burr. Media selection, therefore, will control the
degree of surface luster, making the part bright and shiny or developing a very matte, dull
surface characterized by a completely random scratch pattern, or anything in between.
Part separation
A very important function of the medium is to separate parts during the deburring, cutting,
surface improving or burnishing operations. The media:parts volume ratio is normally used to
control the amount of part-on-part contact which will occur in a vibratory or tumble finishing
operation. At low ratios, considerable part-on-part contact occurs, while at higher ratios part-on-
part contact is limited.
Surface scrubbing
Media have the unique ability to scrub surfaces and physically assist compounds in their
cleaning function. Both abrasive and non-abrasive media are effective in this. They can remove
organic soils, scale, and other inorganic residues. Media come in a wide range of materials in
order to fulfill various needs.
Types of Media
Aluminum media
Aluminium media are typically cast parts and are available in a wide variety of shapes and sizes.
Aluminum scrubs parts and can work in conjunction with cleaning compounds to clean parts.
Since aluminum is fairly nonabrasive it tends to remove surface impurities without affecting the
part's surface qualities. Its cost is typically higher than other cast media. Wear rates are lower
than ceramic but higher than steel media.
Steel
Case hardened, stress-relieved steel preformed shapes are available in a variety of sizes and
configurations. Balls, balls with flat spots, ovoids (footballs), diagonally cut wire similar to angle-
cut cylinders, ball cones and cones (both of which are different from the general concept of
cones) and pins are the most commonly used. Steel media weigh approximately 300 pounds
per cubic foot and are expensive for initial installation, but, because of their minimal attrition
rate and extreme cleanliness, are being more widely used for light deburring applications and
cleaning. Compounds are available to keep steel burnishing media clean and bright for
extended periods.
Other
Shoe pegs, leather, carpet tacks, and many other solid materials have been used at one time or
another in tumble or vibratory finishing for certain applications.
Compounds
Compounds are added to mass finishing processes to assist in deburring, burnishing, cutting,
cleaning, descaling, and inhibiting corrosion. They may be liquids or dry powders. They are
usually broken up into four types: deburring and finishing, burnishing, cleaning, and water
stabilizing.[2]
References
Notes
Bibliography
Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2003), Materials and Processes in Manufacturing
(9th ed.), Wiley, ISBN 0-471-65653-4.
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