Tag Archives: Automotive

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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Automotive Crankshafts, Part 3 – Typical Mass Finishing Machines Used for Crankshafts

Crankshafts are an integral automotive component. Utilized to convert piston movement into rotational motion, these work pieces must provide reliable stability and withstand tensile, compressive, and shear stresses.

Rosler Metal Finishing has extensive experience finishing crankshafts and other automotive work pieces with specially designed shot blasting and mass finishing equipment.

Let’s take a closer look at mass finishing machines offering outstanding processing for crankshafts.

Typical Machines

Built with specific work pieces in mind, Rosler designs several machines to process crankshafts and other automotive work pieces.

Due to their considerable size and weight, the only mass finishing machines capable of handling the deburring of crankshafts after machining are mid- to large-sized tub vibrators or linear, continuous flow vibrators.

Selecting one machine type over the other largely depends on the work piece’s size.

Continue reading Automotive Crankshafts, Part 3 – Typical Mass Finishing Machines Used for Crankshafts

Automotive Crankshafts, Part 2 – Shot Blasting Machines Designed for Crankshafts

As established in Part 1 of our Automotive Blog Series, “Cost-Effective Surface Improvement for Key Engine Components,” shot blasting is an effective technique for the surface treatment of automotive parts including crankshafts.

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.

Typical Machines

Built with specific work pieces in mind, the machines designed to process crankshafts are as diverse as the work pieces they accommodate.

Continue reading Automotive Crankshafts, Part 2 – Shot Blasting Machines Designed for Crankshafts

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

Polishing of Automotive Wheels

3-x-wheels

R 150/2 DL vibratory system with two external motors mounted on processing bowl
R 150/2 DL vibratory system with two external motors mounted on processing bowl

 

Alloy Wheel polishing has been significantly improved by optimising both the processing times and final results. These improvements have been achieved by mounting two motors on the process bowl, providing a stronger and uniform circulation of the grinding and polishing media.

Conventional machines have only a single motor in the centre and on more complex designed alloy wheels, additional machine inertia is desirable.

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Custom Engineered Automation Concepts for Foundries

Robotic Blaster

Automatic blast cleaning with high flexibility for production lines.  A robotic blaster is a combination of a shot blasting unit and a multi-axis robot specially engineered to suit specific applications. It can be deployed for different blast cleaning tasks – from deburring and desanding all the way to evidenced documented shot peening.

roboblastermaximum-reproducibility-fa

Typically automobile manufacturers utilise this highly efficient, compact and noise protected blast system to deburr and surface finish bell/gearbox housings made of magnesium alloy in extremely short cycle times, as low as just 26 seconds.  In order to handle the components from two parallel pressure die casting lines and place them into the shot blasting unit, the robot can be equipped with a double gripper. In the blast cabin, the bell and gearbox housings are shot blasted by six high performance and efficient blast wheels.

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Batch Treatment Of Springs

Leading manufacturers of engine valve and piston ring springs utilise general blast cleaning and shot peening systems.
There are various blast treatment options adapted to a multitude of spring sizes and geometries, depending on your treatment objectives.

Wave spring 1

images 8 - cropped

No other industrial item is produced in such a wide variety.

 

 

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Cleaning Opportunities

Blast cleaning with 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.

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Surf Finishing – A New Standard

sandra wishes!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.

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Automotive Applications – for dry and wet / vapour blasting

To understand what dry and wet / vapour blasting is please see our blog: Blast Surface Preparation and Finishing – What Is It And Why Should We Consider Using It?

Another major industry that justifiably employ dry and wet /vapour blast processes:

Automotive industry

Continue reading Automotive Applications – for dry and wet / vapour blasting