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.
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.
Fine-blanking can achieve flatness and cut edge characteristics that are unobtainable by conventional stamping and punching methods and surface finishing adds additional value.
Fine blanking is capable of combining several steps normally required by traditional stamping making this procedure a very time-efficient process. In a single step, fine blanking can produce a part which would normally require multiple operations in terms of man hours and equipment set-ups. Fine blanking is known and is a recognised method for creating component parts with fully sheared crisp clean edges, close tolerances and profile, eliminating in many cases, secondary requirements.
The production of fine blanks can be formed from various metal types of steel, non-ferrous including zinc, aluminum, aluminum alloys, copper and brass for the automotive industry and other industrial sectors.
Many companies keep the important operation of surface finishing in-house and utilise various systems such as rotary vibrators, centrifugal disk machines and waste water treatment systems. The size and shape of the parts as well as the surface finish requirements, determine which type of mass finishing system is required.
To be cost-effective, mass finishing operations for many and various fine blanked parts require the utilisation of different mass finishing technologies.
Shorter cycle times with centrifugal disk finishing
Centrifugal disk finishing systems are ideal for such applications. When it comes to intensive grinding and polishing, centrifugal disk machines are usually 10 – 30 timesmore productive. Their separation system guarantees batch integrity. However, these finishing systems are somewhat limited by the batch size. For example, a batch of relatively high quantity of parts weighing 400 kg require to be divided into several smaller batches.
Typically, for these larger production capacities, a fully automatic centrifugal disk finishing machine which processes the parts without any operator involvement all the way to depositing the finished parts into dedicated parts bins, is an ideal option. The effluent from this centrifugal disk machine can be cleaned with an effluent treatment process centrifuge after which the cleaned water and compound can be recirculated many times, to achieve considerable cost savings.
Alternatively, consideration could be given to a fully automated rotary system and possibly with several small centrifugal disk finishing machines. The effluent from all these finishing machines can be handled by a waste water centrifuge before being recycled. This allows running several surface finishing processes with optimum results and excellent cost control.
Do you know the difference between standard rotary vibro bowls and high speed processing?
For the processing of larger quantities of component parts a range of high-speed rotary vibrators is an available option, with superior grinding performance and with process economics in mind.
In high speed rotary vibrators, (already in use at numerous manufacturers of fine blanks, stampings, folded or bent, sawn, cold and hot forged component parts), batches of 400 kg can be processed irrespective of whether a batch consists of 10 or 45,000 parts. The performance of high speed rotary vibrators is up to 60% higher than that of standard rotary vibrators which contributes to a quick payback or amortisation.
Click image to watch an automated
centrifugal disk system in operation
Post written by Sandra Banks
Personal Assistant / Digital Marketing