Category Archives: Mass Finishing

Mass Finishing Media, Part 1 – Don’t Navigate the Complex Selection Process Alone

The importance of the media selection in any surface finishing process cannot be emphasized enough. These consumables are essential “precision tools” for achieving the specified finishing results.

Selecting the right media is a complex task. That’s why you should consult an expert such as Rosler for guidance.

Even after a mass finishing process has been established, the media status must be constantly monitored and, if necessary, corrected. When different work pieces are processed or finishing tasks are altered, exchanging the currently used media type with another may be required.

Careful and collaborative media selection is crucial to a mass finishing success.

Continue reading Mass Finishing Media, Part 1 – Don’t Navigate the Complex Selection Process Alone

Mass Finishing Success Requires Constant Operational Focus

When most companies take on capital expenditure projects such as purchasing mass finishing equipment, very careful attention is paid to investing in the most productive, cost‐efficient equipment as possible to achieve the best possible quality. Operational efficiency is often another story.

Once the equipment is up and running routine takes over and less attention is paid to keeping the equipment operating at its peak performance. Whether the machinery is never calibrated to reach its fullest potential or the on-going process is not carefully monitored once the process is dialed in, lacking operational focus can be costly and counterproductive. Figuratively speaking, poorly managed mass finishing operations are pouring money down the drain!

Rosler works with its clients to ensure that our machinery delivers initial success and continues to provide precise, repeatable results long into the future by promoting operational attention and heading off costly mistakes.

Consequences of Inattention

For mass finishing processes, the lack of operational focus may take many forms individually or simultaneously, including:

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New Vibratory Finishing System Enhances Existing Material Handling & Drying Equipment

When it comes to high-volume production of complex aluminum die-castings, Kovolis Hedvikov a.s. (Kovolis) is a sought after partner by numerous car manufacturers and their suppliers. To expand its capacity and achieve more flexibility in the overall manufacturing process, the company purchased a continuous flow vibratory finishing system from Rosler designed to handle a wide work piece spectrum and custom engineered to fit into the available space at the customer’s premises.

About Kovolis

Founded in 1816 as an ironworking operation, Kovolis has focused entirely on aluminum die casting since 1945. Today, Kovolis produces components from nine different aluminum alloys weighing between 7 oz (200 grams) and 18 lbs (8 kg) with different casting technologies including vacuum investment casting and rheocasting.

Their product range includes brakes, power steering systems, turbo chargers, and compressors for air conditioning systems. Kovolis customers are renowned car manufacturers and tier-1 suppliers that also utilize the company as an important partner for product development, machining, heat treatment, and surface finishing services.

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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

Part-on-Part Mass Finishing, Part 3 – Effective Finishing for Ammunition Work Pieces

The gun ammunition manufacturing process requires numerous finishing operations. Since ammunition parts allow for part-on-part mass finishing, Rosler Metal Finishing’s washing and drying machines are ideally suited for ammunition manufacturers.

Available as rotary vibrators and centrifugal disk finishing systems, Rosler’s part-on-part finishing machines can accommodate various ammunition pieces including blanks, cups, deep-drawn casings, cartridge primers, and bullets.

While the manufacturing step and finishing operation of each component varies by work piece and desired result, common mass finishing operations for ammunition based on the specific work pieces are summarized below.

Continue reading Part-on-Part Mass Finishing, Part 3 – Effective Finishing for Ammunition Work Pieces

Part-on-Part Mass Finishing, Part 2 – Rotary Vibrators Versus Centrifugal Disk Machines

As described in Part 1 of our Part-on-Part Blog Series, some forms of mass finishing techniques encourage part-on-part contact to achieve the desired finish. 

In addition to viewing work piece impingement as an asset, this type of mass finishing also eliminated the need for ceramic, plastic, and other types of media. The only additives required for such part-on-part finishing are water and the respective compounds.

Rosler Metal Finishing designs and manufacturers two machines specifically for part-on-part mass finishing known as WTA rotary vibrators and MK centrifugal disk machines.

The applications and benefits of each machine provide a range of part-on-part mass finishing uses for sturdy parts in bulk. Let’s compare their designs.

WTA Rotary Vibrators

Rosler developed special WTA rotary vibrators especially for part-on-part processing. These machines not only allow running the finishing/washing process, but also the subsequent drying stage in one single machine.

Continue reading Part-on-Part Mass Finishing, Part 2 – Rotary Vibrators Versus Centrifugal Disk Machines

Part-on-Part Mass Finishing, Part 1 – Utilizing Work Pieces as the Media

Mass finishing processes require pressure and constant rubbing to achieve the desired finishing results. In most cases, these applications require media specifically selected for its material, size, and shape to act upon work pieces and achieve the required effects. Some mass finishing applications also seek to eliminate or reduce part-on-part impingement or contact to protect delicate and high-value work pieces.

Conversely, part-on-part mass finishing intentionally exposes work pieces to impingement and encourages contact between work pieces and the resulting pressure to create finishing effects without the need for ceramic, plastic, and other types of media. The only additives required for such part-on-part finishing are water and the respective compounds.

Rosler Metal Finishing designs part-on-part mass finishing machines, known as WTA machines, which help reduce cost per piece through the elimination of media consumption and faster processing times.

Ideal Work Pieces

Part-on-part finishing is ideal for small, bulk parts that are made of brass, steel, aluminum, and even small ceramic components.

Continue reading Part-on-Part Mass Finishing, Part 1 – Utilizing Work Pieces as the Media

Automotive Crankshafts, Part 1 – Cost-Effective Surface Improvement for Key Engine Components

Crankshafts are a key component of internal combustion engines, be it mass-produced engines for motorcycles and automobiles, engines for heavy trucks, off-high highway equipment, and even large ships.

Crankshafts convert the reciprocating (up/down) movement of the pistons/connecting rods into a rotational movement that drives the wheels and allows a vehicle to move forward.

Rosler Metal Finishing understands the vital importance of these engine components and has developed specific shot blasting and mass finishing machines to process these pieces to perfection.

A crankshaft with connected rods and pistons
A crankshaft with connected rods and pistons

Materials & Production Methods

Considering that automotive crankshafts weigh around 40-60 pounds and rotate approximately 100 times per second, these parts are exposed to tremendous tensile, compressive, and shear stresses. In addition, combustion forces and piston acceleration in an engine can also cause significant vibration.

Therefore, crankshafts must be made from tough, wear-resistant materials, usually high alloy carbon steel. Typical alloying elements are manganese, chromium, molybdenum, nickel, cobalt, or vanadium.

Continue reading Automotive Crankshafts, Part 1 – Cost-Effective Surface Improvement for Key Engine Components

Spinal Implants, Part 3 – Mass Finishing Versus Shot Blasting Methods

implanted spinal rods
Implanted spinal rods

With worldwide sales at nearly $10 billion annually, there is a high demand for spinal implants. These implants are subject to very specific and strict surface finishing requirements to ensure longevity and fixation to bone.

Mass finishing and shot blasting play key roles in creating the right finish for spinal implants, not only for intermediate surface treatment after forging, casting, machining, additive manufacturing, etc., but also for placing the final surface finish before implantation.

Let’s examine the capabilities of mass finishing and shot blasting for spinal implants and how Rosler Metal Finishing can develop a precise and repeatable finishing process to meet your unique challenges and goals.

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Mass Finishing – Are You Ready to Meet Customer Demand in 2020?

Updating a process to meet increased production demand is a cost-effective way to not only improve your processing times and results, but also increase and prolong your equipment’s usefulness.

Let’s say production has been steadily building over time. How do you know if it’s time to evaluate the process for improvement?

Mass finishing experts suggest examining the final finish accomplished by the process and its ceramic or plastic media and compound usage. Processes in need of optimization will not achieve the desired finish in an acceptable timeframe and will use more media and compounds than necessary.

Continue reading Mass Finishing – Are You Ready to Meet Customer Demand in 2020?