Forge & Foundry, Part 11 – Top Mass Finishing Machines for Cleaning Die Castings

Rosler Metal Finishing has decades of experience in the forge and foundry industries, especially when it comes to mass finishing for die-casted work pieces.

Our Forge & Foundry Blog Series continues with an overview of our top five mass finishing machines for precise cleaning of die castings.

Standard Rotary Vibrators

Media and parts are placed into a circular processing bowl in standard rotary vibrators. The energy from a vibratory motor causes the media and parts to freely tumble over each other. Some models are equipped with an internal separation device for separating the finished work pieces from the media.

Rotary vibrators can be used for batch and continuous feed processing.

The R620 Euro is one of Rosler's standard rotary vibrator models
The R620 Euro is one of Rosler’s standard rotary vibrator models

Rosler’s standard rotary vibrator models include the models EC, Euro, A, and R.

Ideal Work Pieces — Small to fist-sized die-castings such as shoe buckles, furniture fittings, gear shifter forks, electrical components

Continue reading Forge & Foundry, Part 11 – Top Mass Finishing Machines for Cleaning Die Castings

Automation, Part 6—Environmental Considerations of Automation

Technology has transformed almost every aspect of life and the shop floor is no exception. As explored in previous Automation Blog Series posts, Rosler Metal Finishing believes automation represents the new norm in mass finishing and shot blasting. In the face of increasing competition, manufacturing interests will continue to demand lower cost, higher efficiency, and greater flexibility from their chosen surface finishing partner.

Though it would appear that any downsides of automation are outweighed by its benefits, there’s a delicate balance to be struck when it comes to a symbiotic relationship with the world outside of the machine. Having previously discussed how human effort and ingenuity will work in harmony with automated processes, we now turn our attention to environmental considerations—namely, how automated machines used in mass finishing and shot blasting can impact the earth’s resources, and how manufacturers can mitigate that impact.

The International Institute for Sustainable Development notes that the rise of automation has thrust us into a “Fourth Industrial Revolution,” citing energy use, resource use, and ecosystems as the three most critical factors to watch as more automated processes are implemented.

These are important considerations, given that manufacturers often are targeted in headlines about waterway pollution and even global warming, but responsible manufacturing practices can help avoid the most egregious impacts and keep manufacturing operations in compliance.

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Rosler & Lumag – Combining Multiple Solutions in a Single Finishing System

Finding a solution to our clients’ needs is nothing new for Rosler, nor is combining multiple solutions into a single finishing system. Take our work with Polish brake pad manufacturer Lumag Sp. z o.o. (Lumag), for example.

When they faced the challenge of de-oiling, deburring, and surface roughening brake pad carrier plates as part of their punch press process, they turned to us for a cleaning and mass finishing solution.

The Situation

Upon its founding in 1988 by Marek Zak, Lumag specialized in the production of brake linings. As the company implemented its own brake pad manufacturing technology, their products and offerings evolved. In addition to achieving enormous technological progress and applied engineering solutions, Lumag amassed a collection of machinery in need of constant upgrades and integration.

In order to meet the continuous rise of quality and safety standards for its brake pads for drum and disk brakes for commercial vehicles as well as brake pads for passenger cars and motorcycles under the trade name Breck, Lumag needed a partner with automotive expertise who could combine multiple solutions in a single system.

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Forge & Foundry, Part 10 – Shot Blasting Machines Commonly Used for Die Castings

At Rosler Metal Finishing, we have more than 80 years of experience. In that time we have worked with numerous forge and foundry customers. One focus has been the development of shot blasting systems for different types and sizes of die castings.

Our Forge & Foundry Blog Series continues with an overview of our top 10 shot blasting machines for precise, repeatable finishing results with die casted work pieces. Our shot blasting technology includes batch and continuous options.

Continuous Shot Blasting Machines

RMBD Continuous Tumble Belt Machine

Rosler RMBD Continuous Tumble Belt Machine
Rosler RMBD Continuous Tumble Belt Machine

The high-capacity, continuous feed RMBD features an innovative tumble belt work piece transportation system that simultaneously processes and transports work pieces through the system.

Continue reading Forge & Foundry, Part 10 – Shot Blasting Machines Commonly Used for Die Castings

Automation, Part 5 – What Automation Hardware is Available?

As previously discussed in our Automation Blog Series, building a robotically assisted process requires evaluating your surface finishing system along with its problems and goals and selecting the right machine and consumables. Automating a mass finishing or shot blasting process also requires selecting the automated hardware that will best achieve your overall goals and provides the most efficiency in terms of time and manual labor.

An experienced partner such as Rosler Metal Finishing can provide insight and advice on the numerous material handling tools specially designed or adapted to mass finishing and shot blasting process improvement.

Work Piece Loading Systems

Including skip loaders, lift and tip loaders, vibratory feed hoppers, and other tools, work piece loading systems are ideal for small- to mid-sized work pieces handled in bulk.

Continue reading Automation, Part 5 – What Automation Hardware is Available?

Consumable Innovations Improve Finishing Outcomes

True to our mantra of “finding a better way…” Rosler Metal Finishing is constantly working to optimize our consumables. These improvements and additions to our offerings improve process stability, cost efficiency, and productivity of surface finishing processes.

From media composition and compounds to wastewater handling, Rosler is dedicated to constant enhancement in the area of consumables as well as our mass finishing and shot blasting technology.

Media

One such example is Rosler’s development of a plastic media with the grinding and non-chip characteristics of ceramic media. Minimizing the risk of work piece damage, this range of high-density plastic media exactly achieves this frequently requested combination.

High-density plastic media
High-density plastic media
Continue reading Consumable Innovations Improve Finishing Outcomes

Forge & Foundry, Part 9 – Frequently Used Shot Blasting Machines for Forgings, Non-Sand Castings, and Powdered Metal Components

Rosler Metal Finishing has worked in the forge and foundry industries for decades. With more than 80 years of experience, we have developed sophisticated shot blasting systems for countless work pieces including forgings, non-sand castings, and powdered metal components.

Our Forge & Foundry Blog Series continues with an overview of our shot blasting machines most frequently used on these specific types of work pieces.

It is important to understand your work piece and process requirements including whether components will be processed continuously or in batches. When it comes to finishing forgings, non-sand castings, and powdered metal components, our shot blasting machines are divided into three categories based on how the work pieces are fed into the machine: continuous, batch, and specially engineered shot blasting machines.

Continuous Shot Blasting Machines

RMBD Continuous Tumble Belt Machine

Rosler RMBD Continuous Tumble Belt Machine
Rosler RMBD Continuous Tumble Belt Machine

The high-capacity, continuous feed RMBD is available in a heavy-duty version for large forgings and castings, which is equipped with 6 x 40 HP turbines, a steel-slatted work piece transport belt, and a magnetic separator.

Continue reading Forge & Foundry, Part 9 – Frequently Used Shot Blasting Machines for Forgings, Non-Sand Castings, and Powdered Metal Components

Automation, Part 4 – Choosing the Right Machine and Consumables

Rosler Metal Finishing understands that automation integration requires careful planning to ensure the best, most efficient results. Whether for mass finishing or shot blasting, we have more than 80 years of experience helping customers match machines and consumables.

Taking time to evaluate your process needs as a whole will help you and a trusted partner such as Rosler determine what machine and consumables will best suit your automation needs and goals.

How do I choose the right machine?

Selecting the right machine is the most critical step to ensure the success of any automation project. Without the right machine, your automation process is sure to fail or produce disappointing results.

Continue reading Automation, Part 4 – Choosing the Right Machine and Consumables

Innovative Vibratory System Offers Precision Finishing of Delicate Work Pieces

Innovation is at the heart of engineering. At Rosler Metal Finishing, our engineers are constantly finding a better way to help our customers meet their surface finishing needs. That’s why they developed the R 150 DL-2 rotary vibrator.

In addition to uses in the aerospace, automotive, tool and die making, electrical engineering, and equipment manufacturing industries, the R 150 DL-2 has proven its worth in the medical industry as well. In fact, this machine helped Waldemar Link GmbH & Co KG (LINK®) process its endoprosthetic components.

The R 150 DL-2 was an excellent choice for LINK’s new “bi-mobil” hip implant. The implant offers patients a higher degree of mobility by inserting a movable PE joint in the acetabular cup. The PE-joint in turn is clamped to the ball of the hip stem. To minimize friction and prevent premature wear, the inside of the cup requires an extremely smooth surface, which can only be achieved with a high gloss polished finish—something the R 150 DL-2 easily achieves where other surface finishing companies failed.

The perfectly smooth, polished inside of the acetabular cup minimizes friction adn prevents premature wear.
The perfectly smooth, polished inside of the acetabular cup minimizes friction and prevents premature wear.
Continue reading Innovative Vibratory System Offers Precision Finishing of Delicate Work Pieces

Forge & Foundry, Part 8 – Frequently Used Shot Blasting Machines for Sand Castings

With extensive experience in the forge and foundry industries, Rosler Metal Finishing understands that no two shot blasting processes and work pieces are alike. With that in mind, we continue our Forge & Foundry Blog Series with an overview of our machines offering excellent finishing for sand castings.

If you demand precise, repeatable results when shot blasting sand castings, consider the following machines. As always, the experts at Rosler are also available to develop a customized machine to accommodate your unique work pieces and challenges.

RMBD Continuous Tumble Belt Machine

Rosler RMBD Continuous Tumble Belt Machine
Rosler RMBD Continuous Tumble Belt Machine

The high-capacity, continuous feed RMBD is available in a heavy-duty version for foundry applications equipped with 6 x 40 HP turbines, a steel-slatted work piece transport belt, and a magnetic separator.

Continue reading Forge & Foundry, Part 8 – Frequently Used Shot Blasting Machines for Sand Castings

Shot Blasting and Mass Finishing Surface Finishing Experts

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