New Vibratory Finishing System Treats The Internal Channels of Components

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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

The Importance of Vibratory Finishing Media, Compound and Their Production

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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