Shotpeening/Kugelstrahlen/Verfestigungsstrahlen

Shot Peening: an indispensable process

Shot peening is an important and, for safety reasons, an essential process in many industrial sectors, primarily in the  aerospace and automotive industries. Peening dates back to Bronze Age armourers; although in more recent years, this technique has been used by engineers who worked the surface of a component with a "ball peen hammer" in order to induce internal compressive stress  and thus increase service life.

Drive  components (i.e. gears) are often subjected to the shot peening process in order to  induce compressive stress, which considerably reduces the risk of fatigue cracks during their operation.

Technological requirements in all industrial sectors, especially the automotive and aircraft industries, are becoming more and more extensive, particularly with regard to shot peening.

With precise adherence to all shot blasting parameters such as angle of impact, shot-blasting time and shot-blasting pressure (compressed air blasting), discharge rate of the shot-blasting media from the shot-blasting wheel, type of shot-blasting media and degree of surface coverage, the service life of many components such as gearbox components, drive and crank shafts, springs, turbine blades and turbine components in general and many others, increases. The flow of shot blasting media is monitored either magnetically or by weighing devices, depending on whether metal or non-metal shot blasting media is used. Shot blasting media classification, which classifies the media by shape and size, is an important point in shot peening or compression-shot-blasting.

Thanks to our multiple research and development activities and our in-house worldwide test centres, Rösler  is in a position to offer a wide spectrum of  sophisticated shot peening systems.

With precise adherence to all shot blasting parameters such as angle of impact, shot-blasting time and shot-blasting pressure (compressed air blasting), discharge rate of the shot-blasting media from the shot-blasting wheel, type of shot-blasting media and degree of surface coverage, the service life of many components such as gearbox components, drive and crank shafts, springs, turbine blades and turbine components in general and many others, increases. The flow of shot blasting media is monitored either magnetically or by weighing devices, depending on whether metal or non-metal shot blasting media is used. Shot blasting media classification, which classifies the media by shape and size, is an important point in shot peening or compression-shot-blasting.

Shot peening requires absolute accuracy and repeatability.  These are guaranteed by a special, fully-automatic process control with the universal robot shot peening system developed by Rösler for EADS, SNECMA and other aircraft manufacturers for the repair and maintenance of all types of engine components. A large range of engine components can be processed, and their  life improved, using  these systems. They operate fully automatically,  PLC or computer-controlled (Supervisor) and fulfill all technical requirements and specifications.

Compressed-Air Shot-Peening System - for processing components for the aircraft industry.

The shot-blasting nozzles mounted on a 6-axis robot ensure a consistent result with simultaneous rotation of the component. The CNC-controlled system runs fully automatically, which also includes all process controls. This means repeatable, consistent shot peening, in compliance with the most stringent technical requirements.

Various gearbox components for the aircraft industry, with an average weight of 3 kg and a maximum height of 400 mm, are peened in these machines. The shot peening machines are based on a 6-axis robot with two blast nozzles. During the peening process, the parts are rotating simultaneously. A throughput of 30 components/hour can be achieved.  Media classification takes place in a multistage screening system. The throughput is automatically controlled by the Supervisor PC. All machine and process data is displayed and recorded.

This system for the peening of bulky components is  equipped with a 6-axis robot and a 2-axis mobile unit. The media is classified in a spiral screening system.  Two types of shot-blasting media can be used. A  double pressure vessel guarantees continuous shot-blasting without having to wait for it to be refilled during the processing of a component. Loading and unloading of bulky components is handled easily through the large sliding door.

This system is used by a car manufacturer for shot peening gearbox components. If necessary, two different components can be processed independently from one another at the same time.  The peening process is carried out in two stations with four shot blasting nozzles in each station and with rotation of the component. Loading and unloading is done automatically by a handling robot. A throughput of 200 components per hour can be achieved.

Rösler has developed a mini Roboblaster, with a compact machine housing, for peening small turbine blades. This system fulfills the most stringent technical requirements specified by our aerospace customers.

RDT 150/S-5 Satellite Rotary Table System with robotic parts loading and unloading.

The exteriors of toothed gearbox components are descaled and peened in this compact system.

By different rotational directions of the turbines, complete coverage is achieved with an optimum peening effect.

This RDT 250-3S satellite table machine was designed for shot peening disc springs in a continuous process. The RDT 250-3S is equipped with two H42 heavy duty turbines. The processing of parts with a diameter of up to 700 mm and a weight of 50 kg is possible. Special safety partitions allow continuous, full-speed operation of the turbines.
Shot peening is an important and often vital process in the aerospace industries
Controlled and monitored shot peening with Rösler's robotic systems
Snecma and EADS use this shot peening system to increase the fatigue bond strength of engine parts
Blast rooms: safe and environmentally friendly blast cleaning equipment
Rösler R & D programs develop wide range of equipment
Shot peening machine for engine parts
Production of Aerospace Machines
"Excellent peening effect – this system
produces compressive stress levels of
up to 1,500 MPa
"
Due to its modular design the RSA 1400 can be equipped with 6, 8, 10 or 12 rotary satellites
Shot peening is an important and essential process for improving component fatigue life in many industrial sectors

Contact

Tel.:  +49 9533 / 924-0
Fax : +49 9533 / 924-300
E-Mail: info@rosler.com

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