Tag Archives: Castings

Automotive

Rosler & Lumag – Combining Multiple Solutions in a Single Finishing System

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Finding a solution to our clients’ needs is nothing new for Rosler, nor is combining multiple solutions into a single finishing system. Take our work with Polish brake pad manufacturer Lumag Sp. z o.o. (Lumag), for example.

When they faced the challenge of de-oiling, deburring, and surface roughening brake pad carrier plates as part of their punch press process, they turned to us for a cleaning and mass finishing solution.

The Situation

Upon its founding in 1988 by Marek Zak, Lumag specialized in the production of brake linings. As the company implemented its own brake pad manufacturing technology, their products and offerings evolved. In addition to achieving enormous technological progress and applied engineering solutions, Lumag amassed a collection of machinery in need of constant upgrades and integration.

In order to meet the continuous rise of quality and safety standards for its brake pads for drum and disk brakes for commercial vehicles as well as brake pads for passenger cars and motorcycles under the trade name Breck, Lumag needed a partner with automotive expertise who could combine multiple solutions in a single system.

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Shot Blasting

Custom Engineered Automation Concepts for Foundries

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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.

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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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Reference Guides, Shot Blasting

Automated Shot Blast Solutions For Higher Value Castings

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While today’s foundry operations are mostly automated, surface treatment frequently still involves a lot of manual labour resulting in one of the most costly operations within a foundry.  Automated systems tailor-made to the unique requirements of desanding, deburring, cosmetic finishing and overall surface finishing of raw castings not only significantly reduce costs but also increases process safety.

Regardless of how a component is cast, tasks such as desanding, deburring, and surface cleaning are often still carried out manually.  Not only are they extremely time consuming and highly labour intensive but the quality of manual blasting strongly depends on the skills of the person who is blasting, resulting in a process that is neither consistent or documentable.  High quality shot blast results are however a crucial aspect for any foundry product as well as being an important competitive factor.

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Mass Finishing

Applications For Mass Finishing Machines

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To understand what mass finishing is please see our post: Mass Finishing – What Is It And Why Should You Consider Using It?

 

Mass finishing machines come in different shapes, sizes and styles; fromtestzentrum-gs-02-d1[1] 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:

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