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DTSTART;VALUE=DATE:30210824
DTEND;VALUE=DATE:30210825
DTSTAMP:20260420T130811
CREATED:20210824T022959Z
LAST-MODIFIED:20210916T050717Z
UID:646-33186672000-33186758399@www.bvproducts.com.au
SUMMARY:Developments in Mass Finishing Technology
DESCRIPTION:Mass Finishing Fundamentals\nMass Finishing is a term used to describe a group of industrial processes by which large lots of manufactured parts can be processed in bulk economically to achieve a variety of surface effects. These economical processes\, in contrast with hand deburring methods\, develop these effects with a high degree of part-to-part and lot-to-lot uniformity and consistency.  These effects might include edge break\, edge contour\, surface smoothing and improvement\, tool mark blending\, burnishing\, polishing\, super-finishing and micro finishing.  In these types of processes\, energy is imparted to an abrasive embedded or coated loose material known as media that is contained within the work chamber of a finishing machine.  Energy is then transferred from work chamber motion to the media and to the work-pieces or components placed in the media\, by way of a random rubbing or scrubbing action to achieve some sort of edge or surface improvement and refinement.  The surface and edge effects produced are typically non-selective in nature\, unless a part has been partially masked or fixtured.  While edge geometries can be modified (contoured) to some extent\, it would be a mistake to consider these processes for substantial material removal operations that are best left to traditional grinding and machining methods. \nPart Fixturing and Surface Finishing\nIncluded in these mass finishing methods are traditional barrel tumbling\, vibratory and centrifugal finishing.  A closely related set of processes would be fixture-centric processing such as the spin-finish\, drag-finish\, spindle-finish and the turbo-finish methods.  The fixture methods produce results by imparting motion to parts that are fixtured (by either dragging\, rotating or developing a planetary motion) and are immersed in loose abrasive or polishing media.  The force with which part edges and surfaces are interacted with loose media can be considerably higher than that developed by mass media processes\, where parts are placed randomly within the media mass\, and are dependent on the loose media motion to achieve the surfacing results.  Fixturing parts in more conventional barrel or vibratory methods is also not uncommon. This is done for a variety of reasons\, including the need to prevent any part-on-part contact\, but also to increase the amount of force flow of media against part surfaces\, to accelerate cycle times and produce more pronounced surface finish effects. \nPart applications for fixture finishing in conventional equipment vary widely\, to cite some examples:  Some manufacturers of brass musical instruments (trumpets\, french horns\, trombones) fixture brass instrument assemblies in the barrel or vibratory chambers and flow soft polishing granulate media through the assemblies to replace multiple buffing operations.  Similarly\, some manufacturers of medical and surgical implant devices fixture the devices in high-energy centrifugal barrels\, and produce very refined surfaces on cobalt chrome and titanium substrates by processing the devices through a sequence of successively finer loose abrasive operations.  Fixtured processing in vibratory equipment can accommodate even very large structural parts.  This is an important application for large structural aerospace parts. The method can be used to reduce the need for costly manual deburring and finishing methods on airframe components. More importantly\, with the proper sequence of abrasive and non-abrasive operations\, it can be used to develop very significant compressive stress and work hardening characteristics to the parts\, enhancing their wear and fatigue failure resistance dramatically \nOld Dog – New Tricks\, Sequential Processing\nOne trait that many of today’s more sophisticated mass finishing operations share is a reliance on multiple-step sequential processing.  In this type of processing\, very rough surfaces can be brought to a highly polished or micro-finished state.  This is done by initially processing the parts with a coarse abrasive material\, and then following up with a sequence of finer abrasives.  Each of the subsequent steps uses an abrasive material that has been calculated to clear and blend-in the abrasive pattern left in the surface by the preceding step. To use a common everyday analogy\, almost everyone understands that to produce fine finishes in woodworking applications\, it is necessary to use sanding operations with successively finer abrasive grits to produce cabinet or furniture quality surfaces..  The same principle holds true in mass finishing (or even hand-finishing) metal parts\, when very smooth or polished surfaces are required. \nOne time-honored method for producing very refined surfaces is dry barrel processing.  This technology was originally developed and heavily utilized in the northeastern United States as early as the 1930’s; similar methods were developed concurrently in Europe. \nThe method was developed primarily to mitigate the high labor costs associated with hand-buffing large numbers of consumer-oriented articles such as eyewear and jewelry.  This technique was widely accepted as a standard method for producing very refined consumer acceptable product finishes that had previously been the sole province of those buffing methods and is still utilized for these types of applications.  This sequential principle has been adapted for use in other types of equipment for other part finishing applications.  Where reflective surfaces are desired on parts being finished in vibratory equipment\, it is not unusual now to see secondary vibratory processes with burnishing media or dry process polishing media develop those surfaces.  Many processes have been developed for centrifugal disk and centrifugal barrels where three or more steps are utilized in order to bring part surfaces to very low micro-inch surface profiles or to develop very reflective surfaces for cosmetic reasons. \nEven simple tumbling can develop residual stresses that can provide some functional improvements to service life in certain components. High-energy mass finishing methods can magnify this effect many times.  In the early 1990’s some researchers pioneered the use of electron microscope (SEM) analysis to determine or quantify surface finishes as they relate to possible life extension and component functionality. \nThis early work showed that it was possible to improve functionality and service life of many different types of components by a two-fold improvement in metal surface profile and integrity. \nProcesses such as peening are commonly used for metal surface integrity improvement to mitigate crack propagation points and improve service life by improving wear and metal fatigue resistance. It was found that high energy loose media sequential finishing could develop not only compressive stresses but very level\, or negatively skewed plateaued surfaces\, that provided a great deal more bearing load surface to parts which interacted with other part surfaces. \nIn one application\, stamping dies used for forming aluminum can tops were given a useful life of approximately ten times that was anticipated of parts that had not been surface finished with this method.  Another application cited by Richard Gilliam in a technical paper describing centrifugal barrel processing noted that extensive cycling tests conducted by a spring manufacturer.  “This ability to improve resistance to fatigue failure is graphically demonstrated by the results of some tests made by a manufacturer of stainless steel coil springs.  A group of springs was taken from a standard production run.  Half of the sample was finished in the manufacturer’s usual manner of barreling followed by shot peening\, while the other half was CBF-treated for 20 minutes.  The springs were then tested to failure by compressing them to a stress change from 0 to approximately 50\,000 psi.  The results showed that all the springs finished by the conventional method failed between 160\,000 and 360\,000 cycles.  The springs that had been processed by CBF failed at between 360\,000 and 520\,000 cycles\, an average improvement of 60%.” \nIn one application\, stamping dies used for forming aluminum can tops were given a useful life of approximately ten times that was anticipated of parts that had not been surface finished with this method.  Another application cited by Richard Gilliam in a technical paper describing centrifugal barrel processing noted that extensive cycling tests conducted by a spring manufacturer.  “This ability to improve resistance to fatigue failure is graphically demonstrated by the results of some tests made by a manufacturer of stainless steel coil springs.  A group of springs was taken from a standard production run.  Half of the sample was finished in the manufacturer’s usual manner of barreling followed by shot peening\, while the other half was CBF-treated for 20 minutes.  The springs were then tested to failure by compressing them to a stress change from 0 to approximately 50\,000 psi.  The results showed that all the springs finished by the conventional method failed between 160\,000 and 360\,000 cycles.  The springs that had been processed by CBF failed at between 360\,000 and 520\,000 cycles\, an average improvement of 60%.” \nSubstantial compressive stress effects can also be generated in lower energy types of equipment with very dense metal media.  In commenting on this\, John Rogers\, process laboratory manager for the Abbott Ball Co.\, Inc. noted some points made in a company publication: “Steel media is smooth and heavy.  It is not abrasive in action.  Rather\, the media’s weight and strength increase the smoothness and pressure of its finishing action. Workpieces keep their tolerances intact\, gain compressive stress\, and achieve the ultra-clean\, microscopically smooth surface. \nSubstantial compressive stress effects can also be generated in lower energy types of equipment with very dense metal media.  In commenting on this\, John Rogers\, process laboratory manager for the Abbott Ball Co.\, Inc. noted some points made in a company publication: “Steel media is smooth and heavy.  It is not abrasive in action.  Rather\, the media’s weight and strength increase the smoothness and pressure of its finishing action. Workpieces keep their tolerances intact\, gain compressive stress\, and achieve the ultra-clean\, microscopically smooth surface. \nThe wide selection of media shapes and sizes allows full control over the type and amount of contact obtained between the media and the part. Steel media is heavy\, weighing approximately 300 pounds per cubic foot. The media mass forms a dense cushion that produces rapid finishes\, yet does not harm fragile parts. \nAs steel media impinges on a part\, its surface is work-hardened.  The working action imparts compressive stress as a beneficial by-product of the finishing process.  In many instances\, the process can replace steel shot peening as a work-hardening step.  Parts processed with steel media have longer cycle lives and greater resistance to wear as a result of this compressive stress action. \nTurbo-Finish Machines and Turbo-Abrasive Machining\nDr. Michael Massarsky\, the inventor of the Turbo-Finish process\, initially developed the process for improving edge and surface finish methods for rotating parts in the aircraft engine industry.   The process replaces much of the manual deburring formerly required on these types of parts.  TAM machines could be likened to free abrasive turning centers. They utilize fluidized bed technology to suspend abrasive materials in a specially designed chamber. Parts interface with the abrasive material on a continuous basis by having part surfaces exposed and interacted with the abrasive bed by high speed rotational or oscillational movement. This combination of abrasive envelopment and high-speed rotational contact can produce important functional surface conditioning effects and deburring and radius formation very rapidly. Unlike buff\, brush\, belt and polish methods\, or even robotic deburring\, abrasive operations on rotating components are performed on all features of the part simultaneously. This produces a feature-to-feature and part-to-part uniformity that is extraordinary. \nTAM processes share characteristics common to both machining and mechanical finishing processes. A much higher degree of control is possible than is the case with conventional finishing processes. TAM processes can utilize very sophisticated computer control technologies to create processes which are custom tailored to the needs of specific parts. Like machining processes\, the energy to produce the cutting or abrasive action that develops the desired surface effect arises primarily from the rotational energy of the part itself. Unlike both machining processes and manual deburring processes\, with their single point of contact\, TAM processes perform abrasive machining or grinding on all features of the part by abrasive media envelopment. \nHigh speed dry spindle finishing\nDry Spindle finishing or Turbo-Abrasive Machining [TAM] processes were developed originally to address deburring and surface conditioning problems on complex rotating components within the aerospace industry. Aerospace parts such as turbine and compressor discs\, fan disks and impellers pose serious edge finishing problems. Manual methods used in edge finishing for these parts not only were costly and time-consuming but more to the point\, human intervention\, no matter how skillful at this final stage of manufacturing\, is bound to introduce some measure of non-uniformity in both effects and stresses in critical areas of certain features on the part. TAM provides a method whereby final deburring\, radius formation and blending in of machining irregularities could be performed in a single machining operation. This machining operation can accomplish in a few minutes what in many cases took hours to perform manually. It soon became obvious that the technology could address edge-finishing needs of other types of rotationally oriented components such as gears\, turbo-charger rotors\, bearing cages\, pump impellers\, propellers\, and many other rotational parts. Non-rotational parts can also be processed by fixturing them to the periphery of disk-like fixtures. \nAnother important feature of the process is its use of high intensity small abrasive particle contact to produce surface effects. This results in the ability to process intricate or complex part shapes easily. Although the abrasive material used for processing is similar in some respects to grinding and blasting materials\, TAM produces an entirely different and unique surface condition. One of the reasons for this is the muiti-directional and rolling nature of abrasive particle contact with part surfaces. Unlike surface effects created with pressure or impact methods such as air or wheel blasting\, TAM surfaces are characterized by a homogeneous\, finely blended\, abrasive pattern developed by the non-perpendicular nature of the abrasive attack. Unlike wheel or belt grinding\, surface finishes are generated without any perceptible temperature shift at the area of contact and the micro-textured random abrasive pattern is a much more attractive substrate for subsequent coating operations than linear wheel or belt grinding patterns. \nTAM processing can be especially useful when part size\, shape or complexity preclude the use of other mechanical finishing processes. TAM deburrs\, and develops edge and surface finishing effects very rapidly and has unique metal improvement and compressive stress generation capabilities. Aqueous waste treatment and disposal costs are avoided by a completely dry abrasive operation. The process is primarily intended for external surface and edge preparation\, although some simpler interior areas and channels can be processed as well.  Complex geometric forms can be easily accessed. Repeatability and uniformity can be even further enhanced with PLC or computer controlled processing\, and with all features of the part receiving identical and simultaneous abrasive treatment\, feature-to-feature\, part-to-part and lot-to-lot uniformity on parts can be exceptional. \nIsotropic Micro-Finishing and Super-Finishing\nThe process of isotropic micro-finishing and superfinishing is used in applications such as Formula One\, V8 Supercars\, wind turbine transmissions\, helicopter transmissions and other performance critical part applications.  These processes are especially useful to improve surfaces in any area where it is desirable to reduce friction and heat and increase efficiency and service life.  Specialized chemicals and processes have been developed over the past decade in order to produce these important surface effects economically. \nSeveral high-performance engine component manufacturers are sending their products to specially equipped contract finishing service providers for final finish processing. Some of them offer it to their customers as an add-on\, and others build the cost into the components’ selling price. Typical items processed include automotive gears\, motorcycle gears\, crown wheel and pinions\, camshafts\, oil pump internals\, steering rack and pinion\, and crankshafts. Not only does the Vibratory Isotropic Micro-Finishing [VIM] process significantly reduce wear in parts such as the ones listed above but it also enhances the durability and efficiency of metal components\, resulting in cost savings and added value to parts and the manufacturer’s operational budget. \nFor more information please visit: dryfinish.wordpress.com/2017/01/28/developments-in-mass-finishing-technology/
URL:https://www.bvproducts.com.au/event/developments-in-mass-finishing-technology/
CATEGORIES:News
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DTSTART;VALUE=DATE:30210824
DTEND;VALUE=DATE:30210825
DTSTAMP:20260420T130811
CREATED:20210824T023911Z
LAST-MODIFIED:20210916T050708Z
UID:657-33186672000-33186758399@www.bvproducts.com.au
SUMMARY:PostProcess Expands Reach into Australia with New Channel Partner BV Products
DESCRIPTION:National Manufacturing Week\nNot many businesses understand the adage that “good news travels fast and bad news travels faster.” In today’s digital and mobile era\, any experience – good or bad – can travel globally in seconds. For retail brands\, the market is a high-stakes game of exceeding customers’ expectations… \n\nAustralia’s Largest Gathering Of Manufacturing Professionals\n\n\nNational Manufacturing Week is Australia’s largest gathering of manufacturing decision-makers under one roof. It is the one place for the manufacturing community to come together to be inspired\, innovate and connect with one another. \nNational Manufacturing Week allows you to source the latest solutions from the widest range of suppliers all in one place at one time\, and hear from expert speakers about new trends and processes that will position your business to thrive in the global manufacturing sector. \n\n10’000+ Industry Connections\n200+ Leading solution providers\n70+ Expert Speakers\n6 Product Zones\n\n*Based on 10’327 unique visitors at NMW 2017. CAB Audited Media Association of Australia.  \n\nFor more information please visit: nationalmanufacturingweek.com.au \n\n 
URL:https://www.bvproducts.com.au/event/postprocess-expands-reach-into-australia-with-new-channel-partner-bv-products-7/
CATEGORIES:News
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DTSTART;VALUE=DATE:30210824
DTEND;VALUE=DATE:30210825
DTSTAMP:20260420T130811
CREATED:20210824T042724Z
LAST-MODIFIED:20210916T050659Z
UID:700-33186672000-33186758399@www.bvproducts.com.au
SUMMARY:PostProcess Expands Reach into Australia with New Channel Partner BV Products
DESCRIPTION:Partnership With Australian Distributors Of Mass Finishing Equipment Brings PostProcess Into Fourth Continent\n\nPostProcess Technologies Inc.\, the first and only global provider of automated and intelligent post-printing solutions for industrial 3D printing\, has now scaled its distribution into four continents with the signing of BV Products in Australia. In their position as a long-standing innovator in mass finishing equipment and process technology\, BV Products will leverage PostProcess’s data-driven post-printing solutions to deliver dramatic workflow benefits to Australian and New Zealander additive manufacturing users. \nMuch like PostProcess Technologies\, BV Products are trailblazers in the finishing industry. Holding nearly 40 years of experience in subtractive manufacturing\, surface finishing equipment\, and process technology\, BV Products has always taken steps to ensure its unique vibratory finishing technology is the most cost-effective and efficient solution of its kind on the market. This partnership with PostProcess will allow BV Products to expand further into servicing the rapidly growing additive manufacturing sector across industries they are already established in\, including aerospace\, automotive\, medical\, military\, and general engineering. \n“Innovation for mass finishing has always been\, and always will be\, at the core of everything we do\,” said Mark Riley\, Operations Director of BV Products. “While the ability of PostProcess to enable our expansion into additive manufacturing is key\, even more salient is how well our company visions align in providing streamlined\, intelligent approaches to revolutionizing the future of manufacturing. We look forward to delivering software-driven post-printing solutions to the Oceania region.” \n“We could not be more confident in our choice of BV Products to usher in the transformative power of PostProcess’s intelligent solutions to the Australian market\,” commented Bruno Bourguet\, Managing Director\, PostProcess Technologies International. “As another pioneering force in finishing solutions with similar commitments to customer service\, we are thrilled to be partnering with BV Products in our journey to bring full-stack automated post-printing to additive operations everywhere.” \n\n\nAbout PostProcess Technologies:\nPostProcess Technologies is the only provider of automated and intelligent post-printing solutions for 3D printed parts. Founded in 2014 and headquartered in Buffalo\, NY\, USA\, with international operations in Sophia-Antipolis\, France\, PostProcess removes the bottleneck in the third step of 3D printing – post-printing – through patent-pending software\, hardware\, and chemistry technologies. The company’s solutions automate industrial 3D printing’s most common post-printing processes with a software-based approach\, including support\, resin\, and powder removal\, as well as surface finishing\, resulting in “customer-ready” 3D printed parts. Additionally\, as an innovator of software-based 3D post-printing\, PostProcess solutions will enable the full digitization of AM through the post-print step for the Industry 4.0 factory floor. The PostProcess portfolio has been proven across all major industrial 3D printing technologies and is in use daily in every imaginable manufacturing sector. \nAbout BV Products:\nBV Products is an Australian based manufacturer of a range of specialised vibratory finishing equipment and consumables. First registered in August of 1979 it has established itself as one of the leading surface finishing specialists in the southern hemisphere. Originally focused on localised manufacturing\, in recent years the company has started to expand its sphere of operations by forming strategic partnerships with a number of overseas companies who focus in providing equipment based on specific areas of manufacturing such as AM/3D applications. BV Products is now the only manufacturer remaining in Australia and New Zealand and services a very wide range of industries – including defence\, surgical\, energy\, and precision engineering.
URL:https://www.bvproducts.com.au/event/postprocess-expands-reach-into-australia-with-new-channel-partner-bv-products/
CATEGORIES:News
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BEGIN:VEVENT
DTSTART;VALUE=DATE:30210824
DTEND;VALUE=DATE:30210825
DTSTAMP:20260420T130811
CREATED:20210824T042809Z
LAST-MODIFIED:20210916T050641Z
UID:701-33186672000-33186758399@www.bvproducts.com.au
SUMMARY:Next Generation Finishing Technology for Gears and Other Cooperating Parts
DESCRIPTION:(Interview by Ray Chalmers) Dave Davidson has surface finishing in his DNA. His manufacturing beginnings trace to the 1970s working in a longstanding family business that manufactured wooden shoe pegs used for tumble-polishing small plastic items using steam-era machinery. \nTo get a leg up on the technology\, Mr. Davidson\, who remains active as a consultant in the industry\, joined the Society of Manufacturing Engineers’ Burr\, Edge and Surface Technology Division.  With the help of SME mentors\, he developed a line of abrasive and polishing products as well as new mass finishing processes for barrel\, vibratory and centrifugal finishing systems. He is a master at problem-solving customer challenges. \n\n That includes gear-making. Depending on the particular application\, Mr. Davidson describes three mass-finishing methodologies for producing surface finishes on gears that contribute to improved performance and extended service life. They are: \n\nVibratory Finishing\nConventional and predominant\, the familiar vibratory bowls or tubs come in small or large sizes and have been around for decades. There is a relatively recent wrinkle in vibratory finishing\, chemically assisted vibratory finishing\, which uses specially formulated chemical compounds along with non-abrasive media to produce a conversion coating on gears and similar components. This makes it possible to develop level surfaces with micro-finish surface attributes. This technology is especially applicable to automotive gear train systems and engine components such as camshafts and crankshafts and is widely seen among racing teams to acquire performance advantages.\n\n\n\nCentrifugal Barrel Finishing\nThis high-energy method is a mechanically accelerated means for producing edge contour and isotropic micro-finishes on gears. This method is used by a variety of gear manufacturers and high-performance racing teams to improve the surface finish and endurance of gear sets. It is also capable of producing low micro-inch finishes to improve load-bearing qualities of mating surfaces and to develop beneficial compressive stress and cold-hardening properties useful to highly stressed parts. A sequence of processes (analogous to roughing\, finishing and polishing) is often used to develop highly finished surfaces. The high centrifugal forces and speed of this process achieve high-level surface finishes in short cycle times. \n\nOne user\, Mr. Davidson recalls\, pulled racing transmissions after each event for centrifugal finishing\, only to find afterward that gear sets were lasting an entire season. \n A note here about isotropic surface finishes for gears. Isotropic finishing\, Mr. Davidson says\, is a technical term used to distinguish surface finish patterns that are random and non-directional in nature. “This is in contrast to surfaces developed by all common machining and grinding methods\, characterized by Gaussian peak-and-valley distributions parallel to each other that manifest a positive skewed surface with surface peaks and asperities predominating the surface profile\,” he says.\nBy this definition\, all mass finishing methods could be said to be isotropic in nature. The process outlined above\, however\, has been optimized to consistently produce gear surface finishes that will improve overall operational performance and extend service life. \n\nTurbo-Finish or Turbo-Abrasive Machining\nThis is the next-generation gear-finishing method\, according to Mr. Davidson\, who advises and assists Turbo Finish Corp. of Barre\, Massachusetts\, developer of turbo-abrasive machining (TAM). Not wholly machining and not wholly finishing\, one of the properties separating TAM from vibratory or centrifugal gear finishing is that it is a dry method using no fluid media. Parts are fixtured on a spindle\, similar to a horizontal machining center\, and rotated at speeds ranging from 500 to 2\,000 rpm\, fully enveloped in an abrasive media cloud. Highly refined surfaces can be developed when a secondary operation utilizing dry polishing soft granulates\, treated with fine polishing materials occurs as a follow-up to the abrasive deburring\, contouring and smoothing operation.\n“Once you’ve got abrasive particles impinging the part at that level of force\, you’re creating a shot-peening effect without creating shot-peening surfaces\,” Mr. Davidson says. \n From an environmental perspective\, that TAM produces these effects in a waterless\, dry operation is an added advantage. Unlike most of the other mass-finishing methods\, TAM produces no wet-waste discharge effluent that requires treatment or remediation.\nAdmittedly\, TAM investment is more on the capital equipment level\, but users can create edge contours and other surface finishes very rapidly—with 60- to 120-second cycles in many cases—and machines can accommodate large gears in the 48-inch diameter range that would make vibratory or centrifugal finishing inefficient\, if not impossible. \nPerformance Benefits\n\nReduced friction\nIncreased part durability\nImproved corrosion resistance\nReduced wear\nReduced lubrication requirements and cost\nImproved oil retention\nReduced contact and bending fatigue\nImproved pitting resistance\nReduced vibration and noise attenuation\nReduced applied torque requirements\nImproved surface finish uniformity (part-to-part\, feature-to-feature\, and lot-to-lot)\nHigh-quality\, micro-finished surfaces\n\nReduced Friction Benefits\n\nIncreased fuel economy\nReduced contact fatigue\nIncreased power density\nLower operating temperature\nExtended mean time between maintenance overhauls\nReduced maintenance costs\nEliminated break-in\nExtended component life\nReduced metal debris\nReduced part failures\nMinimized overheating\n\nMany gears and gear sets in a variety of industries remain subject to fatigue\, fracture and wear\, Mr. Davidson says. “Such parts can gain substantial improvements in life and performance\, from alterations to their overall surface texture. Improvements in overall smoothness\, load-bearing ratio\, surface profile skewness and isotropicity can\, in many instances\, improve life and performance and cut operational costs dramatically. Manufacturers that have not subjected their parts to an analysis to determine the potential benefits of this kind of processing may be making parts that are not all that they can be.”
URL:https://www.bvproducts.com.au/event/next-generation-finishing-technology-for-gears-and-other-cooperating-parts/
CATEGORIES:News
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