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.
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.
Used in heavy trucks, heavy equipment, and, even,
large ships, crankshafts enable an engine to move a vehicle by converting the
reciprocating (up/down) movement of the pistons/connecting rods into a
rotational movement that propels the vehicle forward.
Depending on their size, weight, and production volume, crankshafts can be blast-cleaned in different machines. Rosler Metal Finishing offers solutions for a wide range of crankshaft types with weights from 15 to more than 500 lbs and lengths from 10 up to 80 in and more.
Built with specific work pieces in mind, the
machines designed to process crankshafts are as diverse as the work pieces they
Automation is changing the way mass finishing and shot blasting processes are delivered. In this five-part blog series, Rosler Metal Finishing will explain what has given rise to automation trends, the human factors of these manufacturing upgrades, and how such automated processes deliver benefits to your business.
Those of us of a certain age remember a portrayal of robotics
that, in hindsight, was rather quaint: human-looking automated machines would
be crisscrossing our landscape, delivering us food and wardrobe, pumping our
gas, collecting our garbage, or – in a more macabre rendering – leading a rise
of the machines that would eliminate the human race.
In reality, Rosie the Robot and the Terminator have not ruled the world, as predicted by Hollywood. Today, faceless, automated machines, arms, and processors are streamlining the way in which products and services are delivered.
In fact, a World Economic Forum article found that the 2020s will be the “age of automation,” with manual jobs making up only 35 percent of the manufacturing labor force by the end of this decade (a drop from 48 percent, as measured in 2016).
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.
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.
At Rosler Metal Finishing, we believe in helping our clients in many industries find a better way to finish and process their products. Part of our success comes from understanding their industry, their process requirements, and market drivers.
Leaders are overwhelmingly positive about their business growth prospects. Nine out of 10 expect revenues to increase and more than half (58%) anticipate strong growth of 5% or higher per year over the next five years. More than two thirds (70%) of manufacturers expect to increase the number of people that they employ over the next five years.
After using Rosler drag finishing systems for a number of years, Airbus Helicopters knew just who to turn to for help with a new helicopter model.
took on the challenging task of finishing larger gear components for the new
design as well as incorporating expanded capacity for their existing helicopter
models, developing an innovative drag finishing system with automatic work
piece clamping and a clever work piece handling system.
on numerous processing trials in our test center, Rosler developed an entirely
new drag finishing concept that meets all customer requirements. Flexible yet
robust, the new drag finisher is capable of finishing approximately 35
different work pieces made from special, high-performance steel alloys with
diameters from 40-800 mm and individual weights of up to 75 kg.
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
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.
Characterized by its sturdy design and numerous technical features, Rosler Metal Finishing’s drag finishing systems are ideal for high value and sensitive parts such as aerospace components that cannot touch each other during the finishing process.
Equipped with a rotary carousel featuring 2 to 12 spindles to mount the parts, work pieces are “dragged” through the media mass. The rotation of both the carousel and the spindles guarantee an even treatment of the parts. Drag finishing offers a metal removal rate that is up to 40 times higher than conventional vibratory finishing.