Category Archives: Shot Blasting

Testing & Expertise Overcome Shot Blasting Challenges

For nearly a decade, Sales Representative and Interim Product Manager of Turbine Blast Equipment Zack Murray has been one of Rosler’s top shot blasting experts. 

Working with customers and our global Customer Experience Centers, he helps develop and test surface finishing machines and media in addition to dialing in specific process parameters.

At times, adhering to the Rosler motto and guiding principle of “finding a better way…” can be difficult and complicated. Luckily, Murray and the entire Rosler team are committed to delivering world-class surface finishing equipment, consumables, and service in a variety of industries.

In this post, Murray shares the most challenging issue he has tackled at Rosler and how the team developed a solution.

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Blade Technology: Straight vs. Curved Blades Explained

As an expert in the shot blasting industry, Rosler knows about blade technology. All shot blasting machines require blades to propel media towards workpieces. While both straight and curved blades are used, each type offers advantages and disadvantages.

What are the Differences?

Straight blades are, as the name suggests, blades that do not have curvature when viewed from the side and do not possess tangential curvature with respect to the turbine. Curved blades are blades that have some degree of curvature when viewed from the side.

As the newer design, curved blades are generally better than straight blades, but they also have some drawbacks related to longevity, maintenance, and cost of ownership.

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New Deflashing Equipment Assists 30-year Customer Increase Production

For over 30 years, Berker GmbH & Co KG (Berker) has trusted Rosler shot blasting equipment in its manufacturing processes.

A member of the Hager Group since 2010, Berker is one of the leading manufacturers of high-end electrical components, from timeless classical switches to intelligent electrical systems for buildings. The company also supplies switches for electrical appliances and automobiles.

The Situation

Berker primarily uses continuous feed systems such as loop and flat belt machines to deflash plastic components including switching elements, electrical outlet covers, frames, and more.

Increased production volume at its Wenden-Ottfingen manufacturing location led Berker to decide to invest in an additional shot blast machine in 2018. The new investment was intended to replace an existing continuous feed loop belt system with the latest deflashing technology.

Its specifications called for increased capacity and high equipment availability.

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Foundry-Specific Shot Blasting Achieves Increased Efficiency

Replacing a shot blasting machine for a long-time customer requires finding a better way to deliver efficient finishing in a faster, smaller, and more maintenance-friendly way. That’s exactly what Rosler delivered when Linde Material Handling (Linde) returned to us for a shot blasting upgrade.

Linde is a supplier of forklift trucks and warehouse equipment and also provides technical intralogistics solutions and services. With a sales and service network spanning more than 100 countries, the company has a global footprint.

For this particular partnership, Linde’s foundry in Weilbach, Germany, challenged Rosler to supply a new shot blasting system capable of finishing and maneuvering the counterweights it manufactures for forklifts. Our solution was a sturdy foundry version of a continuous hanger shot blast machine known as the RHBD 22/27-F.

The Situation

Linde continuously strives to improve its manufacturing operations. As such, the new machines had to accomplish several goals, including faster processing, more flexible material flow, optimized utilization of available space, improved access to all critical maintenance areas, and increased overall efficiency.

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AM Solutions Delivers Post-Processing Solutions for Prototypes & Parts

Knaus Tabbert AG is a leading manufacturer of recreational vehicles. The company’s innovative designs and powerful drive systems for motor homes, caravans, and panel trucks allow for safe, comfortable, and sustainable travel.

At its German headquarters in Jandelsbrunn, Bavaria, Knaus Tabbert utilizes its comprehensive experience and know-how to continuously improve the materials and designs of its vehicles as well as new manufacturing technologies such as additive manufacturing.

Seeking faster and less expensive post processing for its 3D printed prototypes, Knaus Tabbert turned to AM Solutions, a brand of The Rosler Group, to find a better way.

Challenging Post-Processing

From prototyping to production, Knaus Tabbert needed de-powdering and cleaning operations for additively manufactured work pieces.

“On the one hand, we are using 3D printing technology for creating prototypes. On the other hand, we are also utilizing additive manufacturing for producing standard components in volume such as the bracket for an alarm system or the hinge mechanism for the swing-out shower stall,” said Mario Meszaros, Knaus Tabbert Development Engineer.

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Customer Experience Centers Offer Free Surface Finishing Insight & Solutions

During more than 80 years in business, the Rosler team has gained extensive experience in shot blasting and mass finishing for a variety of industries.

In addition to the machinery and consumables we provide, our Customer Experience Centers enable us to demonstrate Rosler’s expertise by processing your samples with settings and requirements tailored to your needs.

Sending your work pieces to one of our 11 test centers around the world is an important step in achieving the perfect surface finishing process.

Learn what to expect from Rosler’s Customer Experience Centers and get the most out of your partnership with Rosler from Sales Representative and Interim Product Manager of Turbine Blast Equipment Zack Murray and Mass Finishing Product Manager Michael Salyers.

What to Expect as a Customer

To achieve optimal processing results, we carry out sample processing step-by-step.

With an emphasis on finding a better way, our process includes:

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Dutch Equipment Manufacturer Increases Flexibility with Automatic Shot Blasting

Blast cleaning is uniquely capable and efficient at delivering the pre-coating surface preparation required for components that must be able to withstand severe ambient conditions including heavy equipment for construction and mining, agricultural machinery, transportation and material handling equipment, and railway equipment and rolling stock.

When Dutch equipment manufacturer Delwi Groenink sought a better solution for prepping its various steel weldments for painting, the company enlarged its manufacturing depth with a new continuous hanger shot blast machine from Rosler.

The Situation

Based in Enschede, Netherlands, the company designs and produces numerous products including placement systems for container pads. Its customers largely work within the material handling, offshore, and transportation sectors.

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Orthopedic Implants, Part 6 – Shot Blasting Improves Longevity

Like mass finishing, shot blasting is an exceptionally versatile surface treatment technology. Its applications range from general cleaning after casting and forging to shot peening and, even, cosmetic blasting for placing a fine, matte finish on the work pieces.

For shot blasting orthopedic implants, Rosler recommends mainly air and occasionally wet blasting systems.  In each process, blast media is accelerated by compressed air and thrown at the work pieces through a blast nozzle, creating an extremely precise blast pattern compared to turbine blasting. Another advantage of air blasting is that it can be used with metallic, mineral as well as organic blast media.

Air blasting and wet blasting schematics

These attributes and many more make this surface finishing method particularly useful in the medical industry.

Examples of Shot Blasting

Shot blasting is an impact system in which small metal or mineral pellets are thrown onto the surface of a work piece at speeds of 200-800 feet/second. The impact on the work piece surface produces the desired cleaning, peening, or texturing effect.

For medical applications, mainly air and wet blast systems are used which generally make a surface rougher. The smoothest finishes achieved with shot blasting are about Ra = 16-32 microinches (= 0.4 to 0.8 μm).

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Wet Blasting Equipment & Media, Part 5 – Careful Media Selection, Additive Use Impact Results 

Wet blasting and dry shot blasting often use similar media to achieve the desired processing result.

Unlike dry blasting that only uses a solid abrasive media, wet blasting processes use a slurry of water with the shot blasting media. This greatly cushions the impact energy on the work pieces, providing gentler, yet effective results for delicate work pieces. The achieved surface finish and appearance will also differ between wet and dry processes, even when the same media type and size are used.

With more than 80 years of experience worldwide, Rosler can supply both the machines and media best suited for your wet blasting needs.

Common Media Types

As long as it is heavier than water and not water soluble, practically any media used for dry blasting can be used for wet blasting.

It is important to consider the usefulness of the media compared to its cost. While a cheaper or longer-lasting media may be available, it may also require additional processing time to accomplish the desired surface finishing. Selecting the most appropriate media for your process requires balancing initial costs with overall results.

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Wet Blasting Equipment & Media, Part 4 – Internal Cleaning, Rebuilds Prolong Machine Lifetime  

While highly effective in a number of applications and industries, wet blasting can be a messy process. Unlike dry shot blasting which produces dust, wet blasting generates a mix of media, dirt, and debris mixed with water mist.

If this water/particle mix is not removed properly the machine itself may be soiled to the point that it cannot be used. Mist which escapes the machine can also cause health hazards to personnel and other equipment in the area.

Rosler builds its wet blasting machines with usability and safety in mind, factoring in precautions and cleaning functions to prolong the machine’s use and ensuring a clean, safe work environment.

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