A number of factors contribute to mass finishing success. Machinery, consumables, compounds, and process water must be evaluated individually and as a whole to create optimal results and stable process conditions.
When considering the flow rate of compound and process water into the processing bowl of a mass finishing machine, careful calibration is required based on the machine type and size, finishing task, condition of the raw work pieces, and process water conditions.
For example, high‐energy machines require a much higher flow rate than vibratory finishing systems. Similarly, work pieces heavily contaminated with oil, grease, and/or dirt require more compound and water than less contaminated work pieces.
Water flow and compound dosing rates are usually determined by processing trials in the test lab of the equipment supplier. Once a finishing process has been defined, the user must make sure that the established water and compound flow parameters are precisely maintained. This requires a well-calibrated and well-maintained dosing system.
At Rosler, we draw upon more than 80 years of worldwide experience to create and maintain effective mass finishing systems and deliver precise results. Our ability to do so is thanks, in part, to understanding the importance of water flow and compound dosing.
Continue reading Mass Finishing Water & Compounds, Part 2 – Precise Water Flow, Dosing Drive Results
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
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
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
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
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
Continue reading Centrifuge technology offers eco-friendly advantages
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
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.
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
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
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