Surface Preparation and Surface Finishing

Roslerblog is a guide to answer questions, solve problems and provide inspiration for, and around issues and challenges facing companies and industries using vibratory finishing and shot blasting processes.

Focusing on key issues you are keen to know more about our experts will share their knowledge so that you can use it to your advantage.

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This blog is intended to introduce and offer both beginners and more experienced engineers a guide to help you with your requirements in the fields of surface finishing and preparation. Our goal with the blog is to share knowledge, encourage discussion and opinion sharing, so please feel free to leave your comments and let us know your views.

We hope you enjoy reading Roslerblog and come back frequently to view the latest posts.

 

welcome post picture as at 29072015

For more information on surface preparation and surface finishing please visit www.rosler.com

 

SANDRA PHOTPost written by
Sandra Banks
Personal Assistant / Digital Marketing

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Surface Finishing Technologies Add Value to “Fine Blanked” Components

Fine-blanking can achieve flatness and cut edge characteristics that are unobtainable by conventional stamping and punching methods and surface finishing adds additional value.

Fine blanking is capable of combining several steps normally required by traditional stamping making this procedure a very time-efficient process. In a single step, fine blanking can produce a part which would normally require multiple operations in terms of man hours and equipment set-ups.  Fine blanking is known and is a recognised method for creating component parts with fully sheared crisp clean edges, close tolerances and profile, eliminating in many cases, secondary requirements.

The production of fine blanks can be formed from various metal types of steel, non-ferrous including zinc, aluminum, aluminum alloys, copper and brass for the automotive industry and other industrial sectors.

Many companies keep the important operation of surface finishing in-house and utilise various systems such as rotary vibrators, centrifugal disk machines and waste water treatment systems.  The size and shape of the parts as well as the surface finish requirements, determine which type of mass finishing system is required.

To be cost-effective, mass finishing operations for many and various fine blanked parts require the utilisation of different mass finishing technologies.

 Shorter cycle times with centrifugal disk finishing

 Centrifugal disk finishing systems are ideal for such applications.  When it comes to intensive grinding and polishing, centrifugal disk machines are usually 10 – 30 times more productive. Their separation system guarantees batch integrity. However, these finishing systems are somewhat limited by the batch size. For example, a batch of relatively high quantity of parts weighing 400 kg require to be divided into several smaller batches.

Typically, for these larger production capacities, a fully automatic centrifugal disk finishing machine which processes the parts without any operator involvement all the way to depositing the finished parts into dedicated parts bins, is an ideal option. The effluent from this centrifugal disk machine can be cleaned with an effluent treatment process centrifuge after which the cleaned water and compound can be recirculated many times, to achieve considerable cost savings.

Alternatively, consideration could be given to a fully automated rotary system and possibly with several small centrifugal disk finishing machines. The effluent from all these finishing machines can be handled by a waste water centrifuge before being recycled. This allows running several surface finishing processes with optimum results and excellent cost control.

Fully automated finishing cell

Do you know the difference between standard rotary vibro bowls and high speed processing?

For the processing of larger quantities of component parts a range of high-speed rotary vibrators is an available option, with superior grinding performance and with process economics in mind.

For the processing of large quantities of component parts

In high speed rotary vibrators, (already in use at numerous manufacturers of fine blanks, stampings, folded or bent, sawn, cold and hot forged component parts), batches of 400 kg can be processed irrespective of whether a batch consists of 10 or 45,000 parts. The performance of high speed rotary vibrators is up to 60% higher than that of standard rotary vibrators which contributes to a quick payback or amortisation.

 

Click image to watch an automated
centrifugal disk system in operation

 

 

Post written by
Sandra Banks
Personal Assistant / Digital Marketing

 

Posted in Mass Finishing, Mass Finishing Applications | Tagged , , , | Leave a comment

New Vibratory Finishing System Treats The Internal Channels of Components

pi02_Domloser_Vibrator_mit_Hubeinrichtung

DL rotary vibrators allow for safe and efficient finishing of the internal channels in complex work pieces

 

One of the most technically challenging aspects of mass finishing is the ability to effectively treat the internal channels of precision components. This is especially true in industries which face very stringent requirements, such as; automotive, aerospace, tooling and medical.  It is essential for these manufacturers to achieve precise finishing results.

Fully automatic operation produces precise and consistent results

A new specialised line of rotary vibrators that do not have an inner dome, which allows for automatic, precise surface grinding, smoothing and high gloss polishing of such specialised components.  New DL vibrators allow for fully automatic and reliable treatment of such inner contours, resulting in excellent finishing results,  achieved in either wet or dry operational mode.  Even with extremely delicate and complex contours the dimensional integrity of the work pieces is fully maintained.  Depending on the components, their original surface readings and the selected finishing process, Rz values of as low as 0.1 µm can be achieved.

R150DL2 machine fixture as at 28042017In this type of machine, one or multiple work pieces may be attached to specially designed fixtures. The complete unit with the attached work piece(s) is then firmly mounted into the DL vibratory finishing system. For certain applications the loading and unloading operation can take place with a pneumatic lifting device, this eliminates the need for entirely removing the media from the work bowl when unloading the fixture with mounted part(s).

The vibratory energy is provided by two high-performance vibratory motors, placed on the outer wall of the work bowl, which is transferred to the work pieces that are mounted to the bottom of the work bowl. The intense vibration causes the processing media to flow through and around contours, internal passages or undercuts in the work pieces, without getting stuck.

Compared to standard vibratory systems, this sophisticated machine design combined with powerful vibratory motors (3,000 RPM) produces a 30% increase in processing intensity, resulting in comparably short cycle times. Adjustment of the imbalance weights and control of the motor speed, with frequency inverters, provides the ability to adapt the processing intensity to match the work pieces and the desired finishing task.

Equipment suitable for a multitude of finishing tasks

DL rotary vibrators are the perfect solution for finishing complex work pieces, such as; housings, pump or fan wheels, blisks, dies and moulds, tools, automotive wheels and a variety of other work pieces.  Ensure you have sample processing trials carried out on your components so that you receive a tailor-made finishing solution, with the highest finishing quality, short cycle times and high cost efficiency.

All DL vibratory finishing systems are equipped with an easy to use control panel, which includes process timers. For wet finishing operations, compound and water are fed into the machine with a precise dosing system.

 

For more information on DL type vibratory finishing machines please click here.

 

SANDRA PHOTPost written by
Sandra Banks
Personal Assistant / Digital Marketing

Posted in Equipment Selection, Mass Finishing | Tagged , , , , , , , | Leave a comment

The Importance of Vibratory Finishing Chips, Compound and Their Production

media-in-liquid-compound

Range of compounds and media

Range of compounds and media

The quality of consumables used in mass finishing is a key factor in surface processing.  Using consumables with a consistent high quality is crucial to attain set surface specifications, process times, costs and to manage considerations to any environmental impact.

There are in excess of 1700 types of vibratory media consisting of various shapes, sizes and incorporating a percentage of abrasive.  These are divided typically between ceramic and plastic families.

Ceramic Media Production

Ceramic media

Ceramic media

A ceramic media has a higher density than that of plastic media.  Ceramic chips of various shapes and sizes are formed, fired and held at certain temperatures and durations; providing an infinite range of variation and capability.

A consistent, supreme quality media is extremely important for the user to obtain a uniquely stable and reproducible surface finishing result.

Ceramic media is manufactured to exacting standards, controlled  in a fully-automated way.

Plastic Media Production

Plastic media

Plastic media

The manufacture of the plastic media is also totally automated.

The plastic media is of a lower density than that of the ceramic media, therefore it is suitable for a more gentle treatment of  critical component parts and softer metals.

The process involves mixing, forming and curing of the media and the whole process is computer controlled and continuously monitored.  This quality standard ensures a consistent wear and cutting performance, and repetitive results during the finishing process.

Surface Finishing Compounds

The right compound for any mass finishing application

The right compound for any mass finishing application

Compounds can be added to the vibratory process, optimising the surface specification for: degreasing, brightening, polishing, corrosion protection and producing surfaces free of stains.

Another important function is keeping the process clean.  The compound continuously flushes tiny metal particulates from the chip media and other contaminants out of the mass finishing system, keeping the media active and the parts free from contamination.

Depending on the specific process, compounds will provide various options of acidity and alkalinity as a pH factor.

Despite compounds being used for many years in mass finishing applications research and development constantly progress new formulations for special applications.

The range of different compounds is broadly diversified:

  • Liquid compounds
  • Recycling compounds
  • Powder compounds
  • Grinding compounds
  • Polishing compounds
  • Dry-polishing compounds
  • Cleaning (degreasing) compounds

Click here for further information on chips and compound

 

Post written by
Sandra Banks
Personal Assistant / Digital Marketing

 

Posted in Mass Finishing Media, Useful Reference Guides | Tagged , , , , | Leave a comment

How To Ensure You Get The Maximum Performance Out Of Your Blast Wheel

Rutten “C” and “Y” Blast Wheel Turbines

c_bladey-blade

The Long-life Rutten has the longest ultimate life expectancy of any, lasting upto 20 times longer than a standard blast wheel or turbine.

This is a highly-engineered blast wheel with exceptionally tight tolerances and built-in specialist superior steel alloys.  Due to the higher value materials and the high specification machining costs of these materials, the initial investment and cost of component wear parts are more highly valued.

However, if maintenance and/or production problems are presently a big issue, the economics of this blast wheel can be demonstrated in ultimately high production speeds and demanding applications.

Least Maintenance And Highest Specifications

Less costs for maintenance up to 16 times higher wear resistance and service life of up to 40,000 operating hours (over 18 years on a single shift).

rosler-gamma-y-wheel rutten-y-wheel

The proven Rutten Long-Life turbines, equipped with components made from carbide steel are characterised by their extremely long service life of up to 40,000 operating hours resulting in significantly higher equipment uptimes and drastically reduced time requirements for maintenance.

They offer substantial savings in energy consumption and spare part costs/hour. The blades have a precise design with a high recognition value and in addition allows the “Y” blade to be turned and used twice. Long-Life turbines are installed in a wide range of new shot blast equipment and can be easily retrofitted into existing shot blast machines.

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Polishing of Automotive Wheels

3-x-wheels

R 150/2 DL vibratory system with two external motors mounted on processing bowl

R 150/2 DL vibratory system with two external motors mounted on processing bowl

 

Alloy Wheel polishing has been significantly improved by optimising both the processing times and final results. These improvements have been achieved by mounting two motors on the process bowl, providing a stronger and uniform circulation of the grinding and polishing media.

Conventional machines have only a single motor in the centre and on more complex designed alloy wheels, additional machine inertia is desirable.

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Replace Blast Wheels and Wear Parts

PART 1             The Case for Superior Blast Wheel / Turbine Efficiency

Your blast wheel is the “business end” of you shot blast machine.   It is the main component which delivers the blast media and performs the blast cleaning or peening process.rosler-gamma-y-wheel

Its performance is vital!

Not only is the blast wheel vital, it is probably the more expensive single item on the machine in terms of performance, productivity, time, maintenance, repair and wear part costs.

Focusing on your future

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Retrofit Blast Wheels And Wear Parts

PART 2   The Case for Superior Blast Wheel / Turbine Efficiency

Less energy consumption up to 25% cost-savings and compliance to environmental policy.

Depending on the size and type of shot blast process i.e. type of machine – Table, Hanger, Barrel, or Through Conveyor, the cost of running per hour adds up.

A simple small table or hanger machine may pull between 11 amps to 60 amps / blast wheel.  A single blast wheel will require 5.5kW to say 30Kw.  Using a nominal 10p / kW hour, costs range from 55p to £3.00/ blast hour x 2,200 hours / annum equates to between £1,210 and £6,600.

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Posted in Shot Blasting, Shot Blasting Applications, Shot Blasting Equipment Modernisation | Tagged , | 2 Comments