Mass Finishing Work Piece Handling Series, Part 2 – Preventing Drop Height Damage

Ensuring drop heights are not too high when raw work pieces are loaded into and exiting a mass finishing machine is an important consideration.

Rosler has extensive experience developing mass finishing machines as well as material handling accessories to create a productive and efficient surface finishing system and prevent drop height damage. When evaluating drop heights and machine configuration needs, it is recommended that you consult an experienced equipment provider to help review key machine aspects and suggest solutions tailored to your unique needs.

Issues to Avoid

Falling from a loading container into a machine as well as moving from the machine into a post-process collection can cause damage to work pieces in the form of nicking and scratching caused by contact among work pieces as well as with the machine itself. More delicate and/or sharp work pieces, therefore, require extra consideration and evaluation of drop heights than sturdy and rounded components.

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Comprehensive Mass Finishing System Provides ‘Shear’ Results for Gardena

Improved productivity, increased production capacity, better quality, and lower costs—a leading garden tool manufacturer tasked Rosler with developing a new mass finishing system to improve the deburring and polishing of garden shear knives.

Rosler provided a solution in the form of a tailor-made Keramo-Finish® process carried out within a double-batch centrifugal disc finishing machine. Known as the FKS 35.1 A2-So, the system includes fully automatic work piece handling and a two-stage process that deburrs and polishes stamped and laser-cut knives. Work pieces are subsequently dried in an energy-efficient rotary dryer and prepared for the next manufacturing step.

The Situation

For more than 60 years, the Gardena division of Husqvarna Group has developed a variety of gardening products and tools. The company’s broad product range includes innovative systems for irrigation, soil cultivation, and lawn, tree, and shrub care. Gardena products are used in more than 80 countries worldwide.

To ensure easy and simple handling, produce excellent cutting performance, and guarantee long service life, the Gardena’s shear components are produced with state-of-the-art manufacturing technologies. Stamping or laser cutting of the upper and lower knives followed by surface finishing is an important step.

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Foundry-Specific Shot Blasting Achieves Increased Efficiency

Replacing a shot blasting machine for a long-time customer requires finding a better way to deliver efficient finishing in a faster, smaller, and more maintenance-friendly way. That’s exactly what Rosler delivered when Linde Material Handling (Linde) returned to us for a shot blasting upgrade.

Linde is a supplier of forklift trucks and warehouse equipment and also provides technical intralogistics solutions and services. With a sales and service network spanning more than 100 countries, the company has a global footprint.

For this particular partnership, Linde’s foundry in Weilbach, Germany, challenged Rosler to supply a new shot blasting system capable of finishing and maneuvering the counterweights it manufactures for forklifts. Our solution was a sturdy foundry version of a continuous hanger shot blast machine known as the RHBD 22/27-F.

The Situation

Linde continuously strives to improve its manufacturing operations. As such, the new machines had to accomplish several goals, including faster processing, more flexible material flow, optimized utilization of available space, improved access to all critical maintenance areas, and increased overall efficiency.

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New Compounds Double Process Water Usability

Experienced manufacturers know that optimum mass finishing process water handling, dosing, and recycling can significantly reduce operational costs and improve finishing results.

With approximately 15,000 different products and the largest, continuously expanding range of media and compounds in the world, Rosler has the machines, consumables, and the experience to develop and maintain precise, efficient, and sustainable surface finishing processes.

Our latest innovation in the field of consumables, Long Life Compounds known as LF compounds, allows mass finishing operations to further optimize their process water cycles.

Advantages

LF compounds utilize a special combination of raw materials to guarantee a remarkably high degree of sanitary stability. So much so that, in most cases, the addition of biocides to process water can be eliminated or greatly reduced when using these new compounds.

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AM Solutions Delivers Post-Processing Solutions for Prototypes & Parts

Knaus Tabbert AG is a leading manufacturer of recreational vehicles. The company’s innovative designs and powerful drive systems for motor homes, caravans, and panel trucks allow for safe, comfortable, and sustainable travel.

At its German headquarters in Jandelsbrunn, Bavaria, Knaus Tabbert utilizes its comprehensive experience and know-how to continuously improve the materials and designs of its vehicles as well as new manufacturing technologies such as additive manufacturing.

Seeking faster and less expensive post processing for its 3D printed prototypes, Knaus Tabbert turned to AM Solutions, a brand of The Rosler Group, to find a better way.

Challenging Post-Processing

From prototyping to production, Knaus Tabbert needed de-powdering and cleaning operations for additively manufactured work pieces.

“On the one hand, we are using 3D printing technology for creating prototypes. On the other hand, we are also utilizing additive manufacturing for producing standard components in volume such as the bracket for an alarm system or the hinge mechanism for the swing-out shower stall,” said Mario Meszaros, Knaus Tabbert Development Engineer.

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Mass Finishing Work Piece Handling Series, Part 1 – Selecting the Best Work Piece/Media Separation Method

One of the first considerations in finishing process development is the ability to effectively separate mass finishing media from the work pieces. If separation cannot be achieved, the process will not be viable. Signs of inadequate separation may include the need for too much manual intervention, lodged media causing downstream process issues, failure to meet finishing standards, or even product recalls.

For processes that do not require work pieces to be firmly mounted to fixtures in the machine, components and media loosely tumble in mass finishing processing bowls and troughs to achieve the desired finishing result. While this interaction is encouraged during processing, swift and precise media separation is crucial before work pieces move onto the next process step.

Rosler has more than 80 years of experience designing mass finishing machines and supplying consumables. Our expertise can help develop the best separation method and settings for your unique combination of finishing, work pieces, and media.

Separation Objectives

If not properly removed from work pieces, media carried out of the machine can cause disastrous results in automated, downstream manufacturing operations such as machining, assembly, painting, etc. The manner in which media and work pieces are separated matters as well.

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Orthopedic Implants, Part 7 – Processing Technology Evolves with Industry Advancements

Due to their precision, efficiency, and economy, mass finishing and shot blasting are an indispensable part of the finishing process for a wide variety of orthopedic implants in different manufacturing stages.

These flexible machines can handle general cleaning; deburring; surface smoothing after casting, forging, stamping, machining, and heat treatment; surface preparation for polishing or coating; and the placement of the final finish on all kinds of implants and medical devices.

With an experienced partner such as Rosler, these processes are also capable of adapting to emerging trends with proper testing and processing trials.

Evolving Technology & Outlook

Orthopedic implant manufacturers are at the cutting edge of medical technology. New materials and manufacturing techniques and technologies are constantly evaluated to improve the performance and longevity of the implants and reduce the manufacturing cost. Two examples are the increased use of ceramics as base material or coating and additive manufacturing.   

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Mass Finishing Machine Settings Series, Part 2 – Determine Imbalance Weight Settings for Consistent Results

Specific mass finishing applications are developed through processing trials. Once defined, users should not deviate from the determined machine settings unless necessitated by work piece or process changes.

Rosler partners with clients to provide testing in our global Customer Experience Centers to demonstrate our capabilities on a specific work piece and to calibrate machine settings. Determining the exact machine settings requires considering and testing multiple factors.

Vibratory Systems

The most common drive systems in mass finishing are vibratory. This refers to actual finishing machines such as rotary, tub, and linear continuous flow vibrators as well as auxiliary equipment like screening systems, vibratory conveyors, buffers, etc.

In all of these cases, the speed of the vibratory motor or the electric motor driving the imbalance unit(s) may have to be adjusted as well as the setting of the imbalance weights.

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Customer Experience Centers Offer Free Surface Finishing Insight & Solutions

During more than 80 years in business, the Rosler team has gained extensive experience in shot blasting and mass finishing for a variety of industries.

In addition to the machinery and consumables we provide, our Customer Experience Centers enable us to demonstrate Rosler’s expertise by processing your samples with settings and requirements tailored to your needs.

Sending your work pieces to one of our 11 test centers around the world is an important step in achieving the perfect surface finishing process.

Learn what to expect from Rosler’s Customer Experience Centers and get the most out of your partnership with Rosler from Sales Representative and Interim Product Manager of Turbine Blast Equipment Zack Murray and Mass Finishing Product Manager Michael Salyers.

What to Expect as a Customer

To achieve optimal processing results, we carry out sample processing step-by-step.

With an emphasis on finding a better way, our process includes:

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Are Your Additive Polymer Parts Breaking During Post Processing?

Growing utilization of additive manufacturing for volume production of plastic components has increased the demand for cost-efficiency and high-quality surface finishes. That’s why AM Solutions, a brand of the Rosler Group, has further expanded its product portfolio with the development of a new media type for post processing of plastic components.

Designed specifically for work pieces printed with MJF and SLS powder-bed-based technology, AM Solutions’ new media permits the safe, cost-efficient finishing of 3D printed components with different shapes and sizes in one single process step and with absolutely repeatable results. This eliminates the time-consuming and costly media changes for different processing stages.

In combination with an understanding of respective printing processes, the new media mix generates a perfect, finely structured, and highly homogeneous surface finish.

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Shot Blasting and Mass Finishing Surface Finishing Experts

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