Tag Archives: Shot Peening

Automation, Part 2 – Why Automation is Beneficial for Your Business

It’s hard to dispute that technology, on the whole, has made our lives easier and more convenient. Myriad functions have been automated – and improved – to mitigate the effects of human intervention. We make purchases more intelligently, we manage data more efficiently, we can control devices with our voices and eye movements, and we ultimately move through life with less left to chance.

In the world of manufacturing, this mitigation of human intervention promises even greater and more measurable, efficiencies. At Rosler Metal Finishing, quality improvements and cost benefits that have resulted from the mechanization and automation of mass finishing and shot blasting operations deliver dividends that transcend the manufacturing floor.

Rosler Multichannel System
Rosler Multichannel System

Since the first microprocessor-controlled machine appeared on the manufacturing floor in 1974, hundreds of new varieties have been shipped across the world. With each improvement, these automated attendants encompass a larger footprint, are able to handle heavier loads and more axes, and require fewer controllers to do their work, according to a McKinsey study.

Automation has revolutionized smaller tasks as well, including simple parts bin handling, lift assists, automatic media adding systems, or multi-step process control systems (like those where noxious chemicals are dosed, without human risk, into the process).

So how do these automation upgrades pay off for you? Let’s start by taking a look at where mass finishing and shot blasting has fit into the manufacturing paradigm. Then we’ll dive deeper into the benefits of today’s automated processes which have a lasting impact on the finished product.

Rosler R 220 SO System for small parts
Rosler R 220 SO System for small parts

The Role of Mass Finishing and Shot Blasting in Modern Manufacturing

When mass finishing and shot blasting were “invented” years ago, their sole purpose was to replace the tedious job of manual deburring, or the stripping of rust and paint from a surface. Early equipment was simple and required substantial operator involvement, but represented great strides productivity and quality improvement.

Over time, both technologies grew into sophisticated surface treatment technologies that have become essential for the proper function of components used across many industries. Today,  state-of-the-art mass finishing equipment is used to place the finishing touch on orthopedic implants like knee femorals, tibia plates, or hip stems before implantation. Complex shot peening systems are also used for extending the service life of critical aircraft components.

Rosler RMT Multi Tumbler System
Rosler RMT Multi Tumbler System

Mass finishing and shot blasting have made a significant contribution towards zero-defect manufacturing with absolutely repeatable, highly cost-efficient, surface improvement processes. To a large extent, this only became possible through further mechanization and automation.

What Are the Benefits of Automation?

When deployed properly, automation offers numerous tangible technical and economic advantages, including:

  • Improved surface treatment quality, including tighter tolerances. As an example, the automation of the shot peening of turbine blades has greatly improved the peening quality as measured by Almen values.
  • Consistent, repeatable quality. A stable process environment means no variations in the output. This can be seen with the automated polishing of orthopedic implants in dedicated mass finishing equipment, which delivers consistent high qualities, batch after batch, day after day.
  • Time savings with reduced manufacturing lead times. As an example, the direct linking of the blast cleaning of steel plates and beams and their corrosion protection in a single, automated preservation line process can drastically reduce turnaround times.
Rosler KON-RRB Preservation Line with transfer system
Rosler KON-RRB Preservation Line with transfer system
  • Improved operational efficiency, which translates to fewer rejects and lower costs. A manufacturer of outboard engines, for example, could reduce its reject rate from 12 percent to 0 by simply converting to an automatic drag finishing process for paint preparation.
  • No need for trained mechanical labor. Automation relieves the pressure of finding qualified, well-trained mechanical labor that understands the complexities of surface finishing in a shrinking marketplace.
  • Cost savings. Automation pays for itself through lower expenditures for personnel, faster turnaround times, and much lower reject rates.
Rosler RDGE 800-8 Wire Mesh Belt System
Rosler RDGE 800-8 Wire Mesh Belt System

Is Automation Always the Best Solution?

It’s clear that automated mass finishing and shot blasting systems produce better surface finishes in a consistent, repeatable manner, reduce the finishing costs, and help reduce lead times. Therefore, for industrial volume production, automation is a “no-brainer.”

However, for work pieces that are produced in very small volumes or are particularly large, bulky and heavy, partial automation may offer a good compromise. This is definitely the case in prototyping shops or foundries and forges making special, custom castings or forgings. As with any business process, you’ll simply want to analyze what the right balance of automation is for your particular application and budget.

Rosler R780 Bowl System with dryer
Rosler R780 Bowl System with dryer

In our next Automation Blog Series post, we’ll take a closer look at the machinery, consumables, and hardware needed to enhance automation in manufacturing operations.

For more information or to discuss your automation needs and challenges, contact us. With more than 80 years of experience in the surface finishing industry, we are confident that we can deliver a solution for your process.

Rosler Tandem R370_12 SE Multi Channel System
Rosler Tandem R370_12 SE Multi Channel System

Shot Peening – Blasting for Longer Component Life

High speed and highly controlled, the process of shot peening has many similarities to the aerospace, automotive, and aviation components it is used on. The machines require absolute precision and reproducibility much like the components they are preparing for long life and changing loads.

Shot peening is a special shot blasting process in which spherical blast media is thrown at the surface of metallic work pieces. The impact energy of the pellets “cold forms” the upper layers of the metal similar to hammering and forging processes.

More on shot peening for longer component life

Three Reasons To Shot Peen Medical Implants

People associate shot peening with automotive and aerospace components.  However, did you know it’s used in the medical implant and component industry.  Bone screws, dental implants, and hip and knee replacement components are just a few of the medical implants that are shot peened.

Continue reading Three Reasons To Shot Peen Medical Implants

MPa and Relationship to Almen Strips

Almen Strip Comparator

This test is widely used on the shop floor as they are comparator measurements, calibrated originally from the MPa measurement results of the x -ray diffractometer.

The requirements for these checks, are specified in standards.

The aerospace industry applies the most rigid of standards when using Almen strips and checking devices.

Continue reading MPa and Relationship to Almen Strips

How to Measure Residual Stress

Measurements – Imperial and Metric explanation

Imperial
Ksi means kilopound per square unit and is derived from psi(lbs/square inch).  Kilo, which is often used in the metric system basically means a thousand (1000).  It comes from the Greek word for 1000. Therefore, a kilopound is 1000 pounds.

Metric
A Megapascal (or MPa) is a variation on a pascal.   Mega in this case means 1,000,000 and again it means “great”.  As you may guess, when using MPa you are usually working with something heavy or with a high pressure!

Both ksi (kilopound per square inch) and megapascal (MPa) are units of pressure measurement – the former is an Imperial unit of measurement and the latter a metric unit.
Ksi values are commonly converted to MPa, as the metric system is the more widely used system of measurement.

Continue reading How to Measure Residual Stress

Measurement Of Compressive Residual Stress Using X-ray Diffraction

A sub-surface compressive residual stress profile is measured using x-ray diffraction measuring equipment.

The X-axis is the measurement of the depth in mm or inches the Y-axis is measure of residual stress in ksi or MPa.

Rösler “in house” laboratory, x-ray diffraction measuring equipment
Rösler “in house” laboratory, x-ray diffraction measuring equipment

Continue reading Measurement Of Compressive Residual Stress Using X-ray Diffraction

What Will Peening Do For My Components?

Shot peening is a cold work process used to enhance the life of metal components, to prevent fatigue, stress corrosion failures and prolong the product life for the component part.

Peening 1Fatigue is the weakening of a material caused by repeatedly applied loads.  It is the progressive and localised structural damage that occurs when a material is subjected to a cyclic loading.

Fatigue occurs when a material is subjected to repeated loading and unloading.   If the loads are above a certain threshold point microscopic cracks will begin to form at the stress concentration points, such as the surface, sharp points in the deviation in shape and the internal grain structure. Eventually a crack will reach a critical size, the crack will elongate suddenly, and the component will break.

Continue reading What Will Peening Do For My Components?

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.

 

 

Continue reading Batch Treatment Of Springs

Rösler Invests In Their Own X-Ray Diffractometer For Precise Measurements

Shot peening increases the fatigue life of components exposed to dynamic stress, for example, of a toothed gear component
Shot peening increases the fatigue life of components exposed to dynamic stress, for example, of a toothed gear component

Shot Peening – for longer component life

The strength and service life of components exposed to high dynamic stresses can be significantly improved by shot peening. In order to be able to quickly develop tailor made shot peening solutions for their customers, Rősler now have their own in house testing facility in Memmelsdorf.

Continue reading Rösler Invests In Their Own X-Ray Diffractometer For Precise Measurements