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The Influence of Selected Brushing Process Parameters on the Tool's Operating Time

Karol Falandys

Karol Falandys

  • Safran Aircraft Engines PolandPoland
  • Rzeszow University of Technology, Faculty of Mechanical Engineering and Aeronautics, Department of Aerospace EngineeringRzeszów, Poland
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Falandys, Karol
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Tomasz Zymróz

Tomasz Zymróz

Safran Aircraft Engines PolandPoland
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Zymróz, Tomasz
 and 
Krzysztof Kurc

Krzysztof Kurc

Rzeszow University of Technology, Faculty of Mechanical Engineering and Aeronautics, Department of Applied Mechanics and RoboticsRzeszów, Poland
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Kurc, Krzysztof
  
Mar 31, 2025
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Published Online: Mar 31, 2025
Page range: 61 - 69
Received: Mar 27, 2024
Accepted: Oct 10, 2024
DOI: https://doi.org/10.2478/ama-2025-0008
Keywords
© 2025 Karol Falandys et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1.

Work station (1 - industrial manipulator, 2 - rotary table, 3 - workpiece gripper, 4 - workpiece magazine, 5 - tool holder)
Work station (1 - industrial manipulator, 2 - rotary table, 3 - workpiece gripper, 4 - workpiece magazine, 5 - tool holder)

Fig. 2.

Tool torque in relations with numer of brushed parts
Tool torque in relations with numer of brushed parts

Fig. 3.

A brush-type tool used in the production process
A brush-type tool used in the production process

Fig. 4.

Implementation scheme of experiment (3 input factors on 2 levels) [42]
Implementation scheme of experiment (3 input factors on 2 levels) [42]

Fig. 5.

The depth to which the brush tool was wear
The depth to which the brush tool was wear

Fig. 6.

Place of measurement of bristle thickness after the test
Place of measurement of bristle thickness after the test

Fig. 7.

Typical parts condition before (left side) and after (right side) of brushing process
Typical parts condition before (left side) and after (right side) of brushing process

Fig. 8.

Location of control points – blade lock
Location of control points – blade lock

Fig. 9.

Results of test- histogram
Results of test- histogram

Fig. 10.

Bristle thickness depending on selected parameters after deburring operation for 30 and 60 pieces
Bristle thickness depending on selected parameters after deburring operation for 30 and 60 pieces

Fig. 11.

Graphical presentation of equation (35) (t – bristle thickness mm, d – brush diameter mm, q – number of processed parts)
Graphical presentation of equation (35) (t – bristle thickness mm, d – brush diameter mm, q – number of processed parts)

Test results – measured bristle thickness

Test number y1 y2 y3 y4 y5 y6 y7 y8 y9 y10 y11 y12 ȳ
1 0.64 0.55 0.55 0.63 0.73 0.64 0.59 0.51 0.41 0.41 0.55 0.56 0.56
2 0.9 0.6 0.83 0.48 0.66 0.74 0.73 0.64 0.43 0.95 0.86 0.86 0.72
3 0.6 0.52 0.62 0.53 0.53 0.54 0.53 0.58 0.55 0.55 0.6 0.54 0.56
4 0.57 0.48 0.46 0.75 0.6 0.55 0.61 0.69 0.66 0.55 0.62 0.7 0.60
5 0.4 0.54 0.42 0.64 0.64 0.69 0.76 0.8 0.7 0.82 0.74 0.85 0.67
6 0.8 0.92 0.75 0.69 0.83 0.8 0.62 0.5 0.62 0.45 0.7 0.65 0.69
7 0.47 0.67 0.3 0.45 0.46 0.4 0.36 0.4 0.38 0.35 0.56 0.5 0.44
8 0.3 0.4 0.55 0.59 0.3 0.63 0.53 0.56 0.64 0.77 0.89 0.49 0.55

Test matrix, columns X1, X2, X3 define the top level (“+”) and bottom level (“−”) of selected process parameters

Test number X1 X2 X3 Rotationai speed rpm Engagement as brush diameter mm Number of brushed parts
1 + + + 2000 200 60
2 + + − 2000 200 30
3 + − + 2000 198 60
4 + − − 2000 198 30
5 − + + 1400 200 60
6 − + − 1400 200 30
7 − − + 1400 198 60
8 − − − 1400 198 30

Results of the tests - the radius of edge break in chosen locations of the detail

Test number Measured value of Edge break, mm
- A B C D E F
1 0.16 0.11 0.17 0.16 0.31 0.29
2 0.15 0.10 0.13 0.15 0.34 0.36
3 0.18 0.19 0.17 0.14 0.25 0.27
4 0.27 0.16 0.19 0.19 0.33 0.3
5 0.17 0.12 0.18 0.14 0.24 0.27
6 0.13 0.11 0.13 0.13 0.29 0.25
7 0.13 0.12 0.15 0.13 0.30 0.30
8 0.14 0.10 0.20 0.13 0.32 0.35

Error variance for individual trials

Test number S2
1 0.0079
2 0.0253
3 0.0010
4 0.0070
5 0.0200
6 0.0171
7 0.0094
8 0.0276
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