For transmission components like gears and shafts, shot peening has become an indispensable step in the overall manufacturing process.
With the RWT swing table machine, Rosler developed a modular equipment concept that can be easily adapted to different technical requirements and offers a maximum in process stability paired with absolutely repeatable peening results and high cost efficiency. One of the numerous customers within the automotive industry utilizing the RWT is an Asian automotive supplier.
As part of a capacity expansion for minivan transmissions, this customer increased annual production to 40,000 units and decided to carry out the required shot peening operation in-house instead of subcontracting it to an external job shop.
The specifications called for a system that can handle around 560,000 single work pieces per year, including 15 different types of gears and shafts. Each work piece type required the development of a specific peening program based on drawings and various work piece materials.
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
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.
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.
While none of these work pieces contain sand, their
surfaces may show oxidization or – in the case of ferrous metals – heavy
scale/rust caused by iron oxide.
All forms of oxidization must be removed to ensure
that subsequent manufacturing operations such as machining, coating, and
painting are economical and efficient. Poorly cleaned work pieces may cause additional
processing, premature wear on milling tools and drill bits, excessive pollution
within coolant systems, and inefficient adhesion of coatings and paint.
Traces of oxidation may also impact the work
Shot blasting and mass finishing have become indispensable technologies for surface preparation and finishing of joint reconstruction implants. Their applications range from surface cleaning, deburring, edge radiusing after forging, casting, additive manufacturing, and machining to surface preparation for different kinds of coatings, shot peening for increasing the longevity of an implant, and placing an extremely smooth, high-gloss finish on the implants before they are inserted into the body.
Are the work pieces sturdy enough to allow for somewhat more aggressive processing or must they be handled gently without any part-on-part contact?
Is batch processing possible or must it be continuous?
Which work piece handling system is best: rotary drum, troughed belt, wire mesh belt, or overhead monorail system?
Can the work pieces be handled by robot, etc.?
Rosler Metal Finishing builds shot blasting machines that are designed to expertly prepare the surface of delicate and sturdy die castings and everything in between. We can design a machine that is perfectly matched to your work piece and process.
Our Forge and Foundry Series continues with a look at the cleaning required for sand castings and the collection of removed contaminants.
Rosler Metal Finishing builds shot blasting machines that are equipped to prepare the surface of sand castings as well as collect removed contaminants for a consistent workpiece finish and the health of the utilized machine and personnel.
What design features must be considered in blast turbines used for the cleaning of sand castings?
Baked-on molding sand, sand cores, and scale/rust on the sand castings are difficult to remove and require turbines with a lot of fire power. Turbines with curved throwing blades, such as Rosler’s Gamma G series, have proven to be exceptionally effective since, compared to straight-bladed turbines, the curvature of the blades generates up to 25 percent higher throwing speeds!
Joint reconstruction implants allow millions of
individuals to regain mobility and reduce pain. Just as surgical skill is
required to implant these artificial joints, so is skillful construction and
finish of the joint components themselves.
Our Joint Reconstruction Series continues with an
overview of the most common materials used for these endoprosthetic implants.
The most common materials used for joint reconstruction implants are currently titanium and titanium alloys and cobalt-chromium alloys. Both materials are very tough, corrosion-resistant, highly biocompatible, and have proven themselves to be absolutely reliable.
Building upon the information shared in our last Forge and Foundry Series post about sand casting, we now turn to the process of selecting and designing machines to specific sand casting operations.
Selecting the right shot blasting machine for your process and work piece means understanding how the work pieces and machine will interact. Here are common questions Rosler Metal Finishing receives when developing perfectly specified solutions for sand casting.
How do work piece
delicacy, size, and weight influence the machine choice?
Before choosing a machine, the following questions
must be asked:
Are the parts sturdy, allowing for aggressive processing, or must they be handled gently, without any part-on-part contact?
Is batch processing possible or must it be continuous?
Which work piece handling system is best: rotary drum, troughed belt, wire mesh belt, overhead monorail system, or heavy-duty crane or trolley on rails for extremely heavy work pieces weighing several tons?
Can the work pieces be handled by robot or is a custom-engineered shot blast system the best solution?
It is extremely important to find a supplier that
can offer a machine that is perfectly matched to the work piece
Getting castings and forgings ready for the subsequent processing steps presents some of the toughest surface finishing challenges. Shot blasting machines can handle all of these tasks from removing residual sand, casting shells, flashing, die marks, or scale. Whether cast iron, steel, stainless steel, super alloys, titanium, aluminum, zinc, or magnesium, the comprehensive portfolio of Rosler Metal Finishing blasting systems for the foundry industry enables the optimal process for any requirement.
Shot blasting is an essential part of most forge
and foundry operations and has been used since the late 1800s. This specialized
surface finishing process throws small metal (or mineral) pellets, called blast
media, onto the surface of a work piece at incredibly high speeds, ranging from
200-800 feet per second. The impact on the work pieces from this process is
what blasts the contaminants from the parts and produces the desired surface
When properly applied prior to finishing, blasting
achieves three key aspects of the finishing process:
Cleans and descales
Creates a uniform
texture on the part and blends the surface