Vibratory tub finishing is a great alternative to manual surface finishing for the aerospace industry.
From engine components and wings to landing gear, properly designed vibratory tubs can accommodate unwieldy work pieces, reduce production times and back logs, and produce a more consistent finish than manual finishing processes.
Our last blog post provided an overview of vibratory finishing’s role in the aerospace industry.
We now turn to specific applications and machine reports to demonstrate Rosler Metal Finishing’s vibratory finishing offerings and capabilities.
What We Offer
Vibratory tub finishing machines from Rosler can be customized to meet your unique aerospace finishing challenges.
Our most useful features include:
Unload gates with external screening units.
Automatic media return.
Integrated rinse stations for finished work pieces.
Gantry systems for easy material handling of heavy, bulky parts.
Ergonomic equipment designs.
All Rosler tub vibrators are equipped with special vibration dampers to prevent the transfer of vibrations to the immediate environment. In order to keep the noise level below 80 dB(A), the machines are placed in special noise
The aerospace industry demands precision and high quality. The processes used to finish aerospace work pieces should adhere to the same rigorous demands.
Gone are the days when the surface of large structural aircraft components is frequently finished by hand. Thanks to the development of large, powerful vibratory tubs, costly manual deburring and grinding of large aircraft components can now be eliminated by highly controlled mass l finishing systems.
Finding A Better Way
Manual deburring and grinding are tedious and costly. Attempting these types of mass finishing by hand usually causes large quality fluctuations with relatively high scrap rates. Above all, manual processes demand highly skilled labor, which is especially hard to find in today’s economy and tight labor markets.
The lack of skilled labor and manual inefficiencies can lead to severe bottle necks in production and long lead times.
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.
In 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.
Any time two metal parts come into contact with each other the resulting friction causes heat build up. These high temperatures cause wear and over time reduce efficiency and eventually create the need for replacement. By creating a smooth and shiny finish the process improves the life and efficiency of moving metal parts. Increased life translates into lower operating costs as well as better performance.
Blast cleaningwith a suitably soft media, cleans fast and is environmentally friendly. It provides a quick reconditioning, reclamation and renewal of dirty, corroded, worn machined components. And is of vital importance to mechanical engineers, in the process of maintenance, component re-claim, rebuilders and re-manufacturers.
“When making a decision between various finishes for your product, seeing the actual finish on the metal is a valuable aid to your decision making and seeing a process in action is even better!”
In recent years, “drag finishing” has become a popular alternative for surface finishing of high value and somewhat delicate metal components.
“Drag finishing” is pulling the components through the media mass thus, honing and polishing in the process.
In a drag finishing system, the parts or components are mounted, fixed and equipped with multiple workstations. Each component is then “dragged” through a circular work bowl filled with grinding or polishing media.
Surf-Finisher – a new standard for automated precision surface finishing
Surf Finishing is a new surface finishing technology that can be incorporated in an automated system combining; loading, handling, processing and even inspection all in one which can give an added benefit of retaining traceability on parts.
The Aerospace Industry is a major precision manufacturing industry that justifiably employ Blast processes Surface Preparationand Finishing. The industry is identfied by several divisional disciplines and each have many applications.
Surf finishing is a fully automatic, dry and/or wet processing method with; extremely short cycle times, high process stability, repeatability and can provide finishing of precisely targeted surface areas for deburring, surface grinding, smoothing and polishing of delicate, high-value components with complex geometries.
Mass finishing machines come in different shapes, sizes and styles; from vibratory bowls and troughs, high energy centrifugal disk machines to drag finishing. Machines can often be chosen in batch and continuous flow versions and as such their application range is as wide as it is varied. below are just some of the possible applications: