Tag Archives: Compounds

Mass Finishing Water & Compounds, Part 1 – Identifying, Correcting Hard and Soft Water Issues

Achieving the desired surface conditions in a mass finishing process requires the machinery, consumables, compounds, and process water to work together in a balanced manner. Independent of the other process elements, the process water itself must be evaluated for hard and soft water issues.

Rosler has more than six decades of experience designing mass finishing machinery, supplying consumables and compounds, and developing processes. Understanding the ramifications of too hard or too soft process water is a key to our success.

Classifications and Measurements

Depending on its geological source, the water used in mass finishing processes may have varying mineral content levels, specifically calcium and magnesium carbonates, bicarbonates, and sulfates. A high amount of mineral content is used to classify the water as “hard”, whereas low mineral content classifies it as “soft”.

Continue reading Mass Finishing Water & Compounds, Part 1 – Identifying, Correcting Hard and Soft Water Issues

Centrifuge Technology, Part 4 – Pre-Conditions and Consumables Enhance Process Efficiency

Establishing and maintaining an effective and cost-efficient process water recycling system requires consideration of a few essential points. Without the proper compounds, additives, and monitoring, even a well-designed piece of centrifuge technology is bound to falter and, eventually, fail.

Rosler has extensive experience in mass finishing, including designing and manufacturing equipment, fine-tuning processes, and supplying the right consumables for a variety of processes. With our knowledge, preconditions and consumables can be calibrated for maximum process efficiency.

Special Recycling Compounds

Mass finishing compounds fulfill numerous tasks such as degreasing/de-oiling work pieces, burnishing/brightening surfaces, and providing a temporary corrosion protection. Above all though, the primary task of the compounds is to keep the media and work pieces clean to achieve the desired finishing goals and keep the mass finishing process stable.

Continue reading Centrifuge Technology, Part 4 – Pre-Conditions and Consumables Enhance Process Efficiency

Forge & Foundry, Part 12 – Media and Compound Selection, Effluent Handling Drive Success

Regardless of the industry, the selection of media and compounds utilized in mass finishing can elevate or hinder finishing results. The handling of effluents – used process water – also factors into a process’ efficiency and end results.

With more than 80 years of experience, Rosler understands the demands of the forge and foundry industries specifically and how to achieve precise and consistent finishing results by combining the latest technology, well-designed machines, and consumables.

This installment of the Forge & Foundry Blog Series highlights how careful media and compound selection along with proactive handling of effluents assist in producing mass finishing efficiencies.

Ingredients for Success

Media and compounds are more than just “rocks” and “soap” thrown into a mass finishing machine. Instead, these consumables are sophisticated tools that can make a mass finishing process a success or a failure.  

Continue reading Forge & Foundry, Part 12 – Media and Compound Selection, Effluent Handling Drive Success

Optimized Finishing Processes Can Reduce Operational Costs

You don’t throw your media out with the waste water, so why would you purchase new mass finishing equipment or muddle through with an inefficient process when optimization can extend the life and enhance the effectiveness of your processing equipment?

Whether a result of increased production needs or in response to poor performance, optimizing your mass finishing process is a great way to reduce operational costs and lower your equipment’s total cost of ownership.

A Proactive Approach

Revising a 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 equipment’s usefulness.

Let’s say production has been steadily building over time. How do you know if it’s time to evaluate the process?

Continue reading Optimized Finishing Processes Can Reduce Operational Costs

Centrifuge technology offers eco-friendly advantages

The mass finishing process creates waste water. This substance known as effluent must be properly processed for reuse or disposal. Centrifuge technology offers solutions for cleaning and/or recycling effluent.

Rosler offers a variety of options to process waste water including flocculation systems and the elimination of vibratory finishing sludge. Each type of waste has unique factors and considerations.

Flocculants for Water Circulation Systems

floc graph

Continue reading Centrifuge technology offers eco-friendly advantages

Mass Finishing 101

Often overlooked in the manufacturing process, mass finishing can help add value in a variety of ways.  Mass finishing can reduce or eliminate manual process steps, improve process consistency, increase throughput, reduce manual labor, and more.

Manufacturing or process engineers in a manufacturing plant do not have to be the expert that knows all the latest details and techniques of the finishing process. They do, however, need to have a good understanding of the basic mass finishing processes that can be applied.

Mass finishing describes a surface finishing method where parts are deburred, smoothed, polished, or cleaned using media (tumbling or vibratory), compounds (finishing soap), and specialized equipment.

Examples of mass finishing equipment include:

Understanding how the different process components, i.e. the machine, media, compound, water, and the incoming part all interact and influence the desired part finish is important. Each of the inputs in itself has a multitude of adjustments and parameters.

Continue reading Mass Finishing 101

Centrifuge Technology Processes Effluent for Reuse and Disposal

In order to achieve the lowest total cost of ownership and the greatest process efficiency, recycling process water used in mass finishing processes is key. Reusing water not only reduces costs in the form of less consumables used, but also enables companies to reduce their discharge and disposal fees by replacing process water less often and complying with water and waste regulations.pollutant table

Waste water from mass finishing applications is often referred to as effluent and must be cleaned for recycling or discharge.

Continue reading Centrifuge Technology Processes Effluent for Reuse and Disposal

Waste Water Recycling – Centrifuge Technology Offers Cost, Environmental Savings

Mass finishing techniques are often used to uniformly prepare and finish work-pieces, but the compounds and liquids used to remove fines and other debris from work-pieces must be dealt with to ensure a repeatable process application. Cleaning and/or recycling waste water produced in the mass finishing process is easily achieved with centrifuge technology and provides opportunities to be more environmentally responsible and save money in the form of reduced labor and materials (cleaning agents and compounds).

How Centrifuges Work

In a centrifuge, waste materials including media and metal fines are often referred to as effluent. The effluent to be cleaned either flows directly from the mass finishing system Continue reading Waste Water Recycling – Centrifuge Technology Offers Cost, Environmental Savings

Compounds are Key to Mass Finishing Success

Machinery and media are nothing in the mass finishing world without the right compound.

A manufactured object can be designed to specifications, but if it doesn’t look and feel finished, it may be rejected.  A metal alloy can be structurally perfect, but surface corrosion may make it less presentable. Process water may work well for initial cycles before contaminants wear down its effectiveness over time.

The right compound for a given mass finishing process can solve each of these problems and more.

Read more about mass finishing compounds

The Importance of Vibratory Finishing Media, Compound and Their Production

media-in-liquid-compound

Range of compounds and media
Range of compounds and media

The quality of consumables used in mass finishing is a key factor in surface processing.  Using consumables with a consistent high quality is crucial to attain set surface specifications, process times, costs and to manage considerations to any environmental impact.

There are in excess of 1700 types of vibratory media consisting of various shapes, sizes and incorporating a percentage of abrasive.  These are divided typically between ceramic and plastic families.

Ceramic Media Production

Ceramic media
Ceramic media

A ceramic media has a higher density than that of plastic media.  Ceramic chips of various shapes and sizes are formed, fired and held at certain temperatures and durations; providing an infinite range of variation and capability.

A consistent, supreme quality media is extremely important for the user to obtain a uniquely stable and reproducible surface finishing result.

Ceramic media is manufactured to exacting standards, controlled  in a fully-automated way.

Plastic Media Production

Plastic media
Plastic media

The manufacture of the plastic media is also totally automated.

The plastic media is of a lower density than that of the ceramic media, therefore it is suitable for a more gentle treatment of  critical component parts and softer metals.

The process involves mixing, forming and curing of the media and the whole process is computer controlled and continuously monitored.  This quality standard ensures a consistent wear and cutting performance, and repetitive results during the finishing process.

Surface Finishing Compounds

The right compound for any mass finishing application
The right compound for any mass finishing application

Compounds can be added to the vibratory process, optimising the surface specification for: degreasing, brightening, polishing, corrosion protection and producing surfaces free of stains.

Another important function is keeping the process clean.  The compound continuously flushes tiny metal particulates from the chip media and other contaminants out of the mass finishing system, keeping the media active and the parts free from contamination.

Depending on the specific process, compounds will provide various options of acidity and alkalinity as a pH factor.

Despite compounds being used for many years in mass finishing applications research and development constantly progress new formulations for special applications.

The range of different compounds is broadly diversified:

  • Liquid compounds
  • Recycling compounds
  • Powder compounds
  • Grinding compounds
  • Polishing compounds
  • Dry-polishing compounds
  • Cleaning (degreasing) compounds

Click here for further information on chips and compound

 

Post written by
Sandra Banks
Personal Assistant / Digital Marketing