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.
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”.
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.
“Glazing” occurs when the surface of the media becomes contaminated with metal fines and other debris from the work pieces. As a result, the media becomes very shiny and frequently looks like a piece of aluminum, brass, steel, zinc, etc.
Because glazed media completely loses its original surface properties, it no longer has any grinding effect. Instead, glazed media creates a sort of uncontrolled burnishing. It also retains dirt and other particles which are then deposited on the work pieces.
The image above depicts (from left) media states include clean, heavily glazed, partially cleaned, and fully cleaned.
Rosler has more than 60 years of media production experience. In that time we’ve seen—and corrected—countless examples of ineffective surface finishing as a result of media glazing.
The importance of the media selection in any surface finishing process cannot be emphasized enough. These consumables are essential “precision tools” for achieving the specified finishing results.
Selecting the right media is a complex task. That’s why you should consult an expert such as Rosler for guidance.
Even after a mass finishing process has been established, the media status must be constantly monitored and, if necessary, corrected. When different work pieces are processed or finishing tasks are altered, exchanging the currently used media type with another may be required.
Careful and collaborative media selection is crucial to a mass finishing 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.
True to our mantra of “finding a better way…” Rosler Metal Finishing is constantly working to optimize our consumables. These improvements and additions to our offerings improve process stability, cost efficiency, and productivity of surface finishing processes.
From media composition and compounds to wastewater handling, Rosler is dedicated to constant enhancement in the area of consumables as well as our mass finishing and shot blasting technology.
One such example is Rosler’s development of a plastic media with the grinding and non-chip characteristics of ceramic media. Minimizing the risk of work piece damage, this range of high-density plastic media exactly achieves this frequently requested combination.
Taking time to evaluate your process needs as a whole will help you and a trusted partner such as Rosler determine what machine and consumables will best suit your automation needs and goals.
How do I choose the right machine?
Selecting the right machine is the most critical step to ensure the success of any automation project. Without the right machine, your automation process is sure to fail or produce disappointing results.
Among the various technologies used for finishing the surface of medical instruments, mass finishing and shot blasting play a key role, not only as intermediate steps but also for placing the final, finishing touch on these components.
Besides the right material selection, surface treatment is an essential component of the overall manufacturing process of medical instruments. Only high-quality surface finishes guarantee the required functionality, high sterility, corrosion resistance, and absolute reliability that most medical components require, while also providing a satin, non-glare appearance.
Whether it be a process for polishing, surface cut down, grinding, deburring, cosmetic finishing, or just cleaning, an appropriate media is available. Choosing the media can seem daunting at first, with over 1700 various media and compounds available. Therefore, sample trials are of significant importance. Here are three considerations to think about when choosing the right media: Read more about media purchasing considerations