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Millioneninvestition in die Produktion

Durch die Millioneninvestition am Standort Untermerzbach wird die Produktion zukunftsorientiert ausgebaut. Das neue CNC Fahrständer Fräs- und Bohrcenter trägt dazu bei, den hohen Qualitätsstandard der Rösler Maschinen zu sichern und die Produktivität weiter zu erhöhen. Mit der neuen Anlage können bis zu 7.000 mm lange und 3.100 mm breite Großteile hochflexibel bearbeitet werden. Dafür sorgt die Möglichkeit der Pendelbearbeitung, durch die Teile parallel vorgerüstet werden können. Die Abmessungen des CNC Fahrständer Fräs- und Bohrcenters im Rösler-CI machen die State of the Art-Maschine gleichzeitig zu einem attraktiven Blickfang beim Rundgang durch die Produktion in Untermerzbach.

Mass Finishing Machine Settings Series, Part 1 – Improve Machine Function with Proactive and Responsive Observation, Calibration

Even if the finishing media and compound/water are managed perfectly, without a well-functioning machine a mass finishing process is doomed to fail. Focusing on a few essentials will ensure that a mass finishing machine is performing as intended. From machine settings to preventative maintenance and troubleshooting tips, Rosler has the experience and insight to keep mass finishing machines running efficiently. The Right Machine Settings The speed at which a machine is running is critical to the success of a finishing process. If the machine is running too slow, the finishing results, deburring/edge radiusing , surface grinding , etc., might not be achieved at all or only after excessively long processing times. If the machine is running too fast, the work pieces may be damaged by scratching, nicking, or bending. Excessive speeds will also cause the media to wear much faster without the benefit of shorter cycle times. Beyond speed, other machine settings must be taken into consideration based on the specific machine type. Rosler's R 420 EC vibratory tub machine with media Vibratory The energy required to move the media and part mix in a rotary , tub , or linear continuous flow vibrator is created by the vibratory motor and imbalance weights. As such, the motor speed, setting of imbalance weights, and the mass of imbalance weights are adjusted to match the processing needs. Rosler's FKS centrifugal disc machine from above Centrifugal Disc Finishing Rotation of the spinner in the bottom of the processing bowl produces energy needed to accelerate the media and parts batch in a centrifugal disc finishing machine . The speed of the drive motor and the ribs on the spinner should be regularly evaluated to ensure effective energy transfer. Rosler's R6/1000 with automatic loading robot Drag Finishing Within a drag finishing machine , the movement of the fixtured parts through the stationary media mass is powered by the rotation of the carousel, work station(s), and, sometimes, individual work station spindles. The speed of each component as well as the angle of the work stations determine the intensity of the process. Immersing the part deeper in the mass increases the processing intensity. Rosler's R 1-1 TSA plunge finishing machine Plunge Finishing In a plunge finishing machine , the fixtured part moves in relation to the static media. The motion is driven by the eccentric spindle rotation and rotational and/or vertical oscillation. The rotational speed of the motor driving the spindle(s) as well as the frequency and amplitude of the oscillation determine the processing intensity. As with drag finishing, immersing the part deeper in the mass increases the processing intensity. Rosler's surf finishing machine Surf Finishing Also referred to as spin finishing, surf finishing machines rely on a rotating processing bowl with the media and a stationary work piece holder to introduce the required energy for the finishing process. The parts are fixtured to the work piece holders on a robot arm or a slowly rotating spindle. Possible points of adjustment and evaluation include the rotational speeds of the processing bowl. The angle of the work piece holder and the immersion depth also affect the processing intensity. A six-axis robot can provide almost infinite degrees of process intensity for different areas of the same part. Regardless of the machine type, correctly connecting the motor drive is vital. The rotational direction of the motor is one of the main causes for a poorly running process after a machine has been repaired or moved to a new location. Such a small mistake can have disastrous results by completely ruining a mass finishing process. Preventive Maintenance As with any other manufacturing operation, preventive maintenance will allow you to achieve consistent, high‐quality results with your mass finishing equipment. Operator manuals usually provide detailed guidelines for properly maintaining your equipment. Reputable machine producers will provide preventive maintenance checklists with a quick overview of the essential equipment and process aspects. If regularly checked, these steps will ensure that the desired finishing results are consistently achieved without any unnecessary equipment downtimes. In addition, the checklists provided by Rosler also include valuable pointers for managing the grinding and polishing media levels as well as the compound and water flow rates. Troubleshooting Tips Optimal interaction between equipment, media, compound, and water are the key to achieving good mass finishing results. Small changes in the surface condition of the raw work pieces (for example, an oil change in a stamping operation), use of a different compound and/or different media, use of a different water source with harder or softer water, a poorly calibrated compound dosing pump, plugged machine drains, the wrong wiring of a drive motor, the wrong motor speed, incorrectly set imbalance weights, and a number of other factors can drastically impact a mass finishing process. For situations where the finishing results are no longer what they are supposed to be, machine manufacturers can provide a checklist of troubleshooting tips and suggestions as to what might have gone wrong. Qualified service and process technicians can also provide an assessment of your system. The Rosler Way With more than 80 years of experience, Rosler has extensive knowledge in identifying ideal setting configurations as well as developing the machines themselves. Contact us to discuss your machine needs and issues, both proactive and reactive. The Mass Finishing Settings & Imbalance Weights Series will continue with, “Part 2 – Determine Imbalance Weight Settings for Consistent Results.” Sign up for enews alerts to follow the Rosler Blog and be notified of new posts!

Intelligente Lösungen für effizientes, automatisiertes Entgraten

Die weitere Optimierung von Qualität, Produktivität und Kapazität veranlassten einen führenden Hersteller von Kunststoff-Spritzgussteilen, vorhandene Strahlanlagen zu ersetzen. Entschieden hat sich das Unternehmen für Lösungen von Rösler: Eine RWS 1200, die voll integriert in Fertigungszellen das prozesssichere, automatische Entgraten der Werkstücke als Einzelteile ermöglicht. Für die chargenweise Bearbeitung schüttfähiger Teile fiel die Entscheidung auf die Muldenbandchargenstrahlanlage RMBC 1.1-S. Durch ihr hohes Chargenvolumen und kurze Taktzeiten ersetzt sie gleich drei bisher eingesetzte Strahlanlagen.

Kosten reduziert, Qualität und Reproduzierbarkeit optimiert

Für eine optimale Patientenversorgung müssen die verschiedenen Bereiche von Hüftschäften unterschiedliche Oberflächenanforderungen erfüllen. Um am Halsbereich der Implantate eine glatte und hochglanzpolierte Oberfläche herzustellen, ersetzte ein Präzisionsteilehersteller das manuelle Schleifen mit anschließender Elektropolitur durch einen zweistufigen, automatisierten Gleitschliffprozess. Der Schleppfinisher R 4/700 SF von Rösler ermöglicht dabei die präzise Einzelteilbearbeitung von zwölf Hüftschäften gleichzeitig. Neben deutlichen Kosten- und Zeiteinsparungen resultieren daraus eine verbesserte und reproduzierbare Qualität. Die spanende Herstellung von feinmechanischen Komponenten und Baugruppen ist das Metier, dem sich die im niederösterreichischen Pottendorf ansässige MBN Präzisionstechnik GmbH seit 20 Jahren widmet. Der Schwerpunkt liegt in der Produktion von chirurgischen Implantaten und Instrumenten aus Titan und Edelstahl. Das entsprechend DIN 13485 zertifizierte Unternehmen verfügt nicht nur über einen hochmodernen Maschinenpark inklusive Laserbeschriftungslösungen und 3D-Messtechnik, sondern auch über Reinräume für das Beschichten und sterile Verpacken der Produkte.

Hochautomatisierte Strahllösung für Getriebeteile von E-Fahrzeugen

Mit einer neuen Durchlaufstrahlanlage inklusive hochautomatisiertem Teilehandling von Rösler baut ein deutscher Hersteller seine Getriebefertigung für Elektroautos aus. Durchgesetzt hat sich die Strahllösung aufgrund ihrer hohen Leistung, wartungsarmen Ausführung sowie Langlebigkeit. Die guten Erfahrungen mit einer nahezu baugleichen Strahlanlage, die bei dem OEM seit 2016 in Betrieb ist, spielten ebenfalls eine Rolle.

Non-Foaming Plastic Media Optimizes Finishing Process

While the optimization of mass finishing processes mostly focuses on the machinery utilized, Dörfler & Schmidt Präzisionsfinish GmbH (Dörfler & Schmidt) has shown that a simple shift such as using a different media can create significant process optimization. By switching to a new, non-foaming plastic media from Rosler , the post-processor achieved improved process stability, productivity, and efficiency. Meeting Varied Needs Founded in 1998, Dörfler & Schmidt offers a wide range of surface finishing including deburring , edge radiusing, surface smoothing and polishing , creating matte and textured finishes, descaling , and cleaning . The family-owned business located in Kammerstein, Bavaria, works with automotive , machinery building, electronics, medical engineering , jewelry , and a variety of consumer goods customers. “We have to deal mostly with requests for deburring and edge radiusing,” said Dörfler & Schmidt Management Assistant Felix Dörfler. “For example, on tools like milling tools and cutting inserts we have to create a precise edge radius. “Other work pieces, such as bearing rings, must have precisely defined surface roughness readings after the finishing operation while jewelry and accessories must have an optically pleasing finish.” Work piece materials range from metal, plastic, and ceramic to glass and wood in dimensions as little as a fraction of an inch (a few mm) up to 25 in (60 cm). Working with a Proven Partner Dörfler & Schmidt operates 33 different machines capable of handling a broad range of different mass finishing and shot blasting technologies. “To handle various work piece materials, we employ different process water cleaning and recycling systems,” Dörfler said. “For this purpose, we are utilizing five centrifuges , which, like the overwhelming majority of our mass finishing equipment, were supplied by Rosler.” When it comes to consumables , Dörfler & Schmidt primarily uses Rosler products as well. “The consistently high quality of the Rosler media and compounds, as well as the excellent process development support and optimization by their Customer Experience Center , are just a few reasons why we’ve relied on solutions from Rosler right from the beginning,” Dörfler said. The Situation “For the deburring and edge radiusing 40-mm-long stainless steel wire segments, we need an excellent grinding performance with a high metal removal rate,” Dörfler said. “However, foaming during the finishing process created a buffer between the work pieces and the media, reducing the grinding effect. “Therefore, the desired finishing results could no longer be achieved within the prescribed cycle time,” he said. In addition to Prolonged cycle times and an inability to separate media from finished work pieces after processing, the foaming issue was even carried over to the process water cleaning system, where foam seeped out of the centrifuges, soiling the system itself and the immediate environment. A Smart Solution The extent of foaming issues largely depends on the hardness of the process water and can often be remedied with special additives. When the company’s Rosler Sales Agent learned of the problem, he recognized that additives weren’t effective and suggested the newly developed “N” series of non-foaming plastic media from Rosler. Dörfler & Schmidt subsequently joined a select group of companies who tested the new media series. Since the non-foaming media version is identical to standard plastic media in identical shapes, sizes, and grinding performances, it could be swapped in without finishing process modifications. The Results More than a year later, Dörfler & Schmidt is still using the non-foaming media. Impressive results are achieved within the prescribed cycle time and separation issues have also been resolved. The media switch also greatly simplified the monitoring of the finishing process. Eliminating the need for reprocessing significantly improved the process’ overall cost-efficiency and extended the usable life of the process water, reducing the consumption of additives and contributing to increased sustainability. “We have been using the non-foaming media in two machines, and we have found that the grinding performance and the wear rate are absolutely identical with the standard version,” Dörfler said. “The new media helped us to make our processes more cost-efficient without affecting the quality of the finishing results. “For this reason, we will switch more plastic media types to the non-foaming version.” The Rosler Way All standard Rosler plastic media varieties have been available in non-foaming “N” versions since 2021, adding to the more than 15,000 equipment and consumable products we offer. Contact us today to discuss your mass finishing challenges and our solutions!

Wet Blasting Equipment & Media, Part 5 – Careful Media Selection, Additive Use Impact Results

Wet blasting and dry shot blasting often use similar media to achieve the desired processing result. Unlike dry blasting that only uses a solid abrasive media, wet blasting processes use a slurry of water with the shot blasting media. This greatly cushions the impact energy on the work pieces, providing gentler, yet effective results for delicate work pieces. The achieved surface finish and appearance will also differ between wet and dry processes, even when the same media type and size are used. With more than 80 years of experience worldwide, Rosler can supply both the machines and media best suited for your wet blasting needs. Common Media Types As long as it is heavier than water and not water soluble, practically any media used for dry blasting can be used for wet blasting. It is important to consider the usefulness of the media compared to its cost. While a cheaper or longer-lasting media may be available, it may also require additional processing time to accomplish the desired surface finishing. Selecting the most appropriate media for your process requires balancing initial costs with overall results. Common types of wet blasting media include (top, from left) brown, white, and pink fused aluminum oxide; glass beads, ceramic beads, (bottom, from left) stainless steel shot, stainless steel grit, and polycarbonate beads. The most common wet blast media include: Brown, white, and pink fused aluminum oxide – Widely used for blast cleaning, this media type’s hardness makes it ideal for surface cleaning and paint preparation. Glass beads – Useful in wet cleaning and light peening applications, glass beads can also be used for light deburring and cosmetic blasting. Ceramic beads – This media’s high bulk density produces a higher impact intensity than glass beads and is useful for general surface cleaning and shot peening. The spherical beads provide a bright matte finish. Stainless steel shot – While useful in special cleaning and shot peening applications, this media type is not suitable for non-ferrous, soft metals. Stainless steel grit – The high bulk density and angular shape of this media produces an excellent cleaning effect, but is not suitable for non-ferrous, soft metals. Polycarbonate beads – This media is useful for very gentle cleaning applications and cosmetic blasting. Water Additives Rosler offers a wide selection of additives and compounds. The addition of certain chemical additives to the process water will support the wet blasting process and help extend the usable life of the process water. Popular additives in wet blasting processes include: Degreasing compounds – These surfactants chemically augment the mechanical cleaning effect of the wet blast process. They are only applicable when the work pieces are covered with grease or oil. Heavy contamination must be removed before wet blasting. Corrosion protection compounds - Such compounds provide temporary corrosion protection for a few days on ferrous work pieces. Biocides – These additives prevent bacterial contamination of the process water/slurry. During downtimes and inactivity such as the holidays or weekends, bacteria grows more easily. The addition of a biocide prevents such contaminations and allows process water to be used for longer periods of time before being replaced with fresh water. Flocculants – Used for augmenting the cleaning effect of centrifuges, flocculants aid in the removal of contaminants from the process water by encouraging contaminates to “floc” or group together, making the larger pieces of debris easier to remove for the system. Water hardeners - If very soft water is used (< 70 mg/L or 4.2 grains per gallon), foaming in the wet blast machine and the filtration system can become an issue. In such cases, a water hardener is useful in eliminating and/or avoiding issues. The Rosler Way As the utilization of wet blasting increases, Rosler reminds manufacturers to review their traditional, dry shot blasting applications and consider if wet blasting could provide additional efficiencies, reduced costs, and better results. We have extensive experience in wet blasting. Whatever your challenges are, we are confident that we can deliver a solution. Contact us to discuss your needs today! The complete Wet Blasting Equipment & Media series includes: Part 1 – “Machines Range in Complexity, Uses.” Part 2 – “Technical Components Combine for Systematic Success.” Part 3 – “Maintain Slurry Concentrations for Finishing Consistency.” Part 4 – “Internal Cleaning, Rebuilds Prolong Machine Lifetime.” Part 5 – “Careful Media Selection, Additive Use Impact Results.”

US-Gigant Wheel Pros kauft 41 Rösler-Felgenbearbeitungsanlagen

Torq Thrust – ein in den 1960er entwickeltes Felgenmodell der Marke American Racing – ist das legendärste und am häufigsten kopierte Raddesign aller Zeiten und heute noch so aktuell wie damals. 2008 übernahm Wheel Pros, führender Hersteller und Distributor von Markenrädern für den Aftermarket, die Marke und entschied sich 2020 für das Reshoring der Produktion aus China. Dafür wurde in Auburn, Alabama eine komplett neue Fertigung aufgebaut. Aufgrund guter Erfahrungen empfahl der Vice President of Marketing von Wheel Pros und frühere Eigentümer des Wettbewerbers MHT, der ebenfalls übernommen wurde, Rösler als Partner für das Oberflächenfinish von rund 50.000 Felgen jährlich. Die aus Aluminiumguss hergestellten Felgen mit Durchmessern von 15 bis 20 Zoll und Breiten zwischen 7 und 9 Zoll sollten automatisiert bearbeitet werden. Dabei ist ein mindestens ebenso glänzendes Finish reproduzierbar zu erzielen wie durch die vorhergehende manuelle Politur und das in vergleichsweise kurzen Prozesszeiten.

Linde MH setzt auf Hängebahn-Durchlaufstrahlanlage in robuster Gießerei-Ausführung

Linde Material Handling (MH) ein weltweit führender Hersteller von Gabelstaplern und Lagertechnikgeräten sowie Anbieter von Dienstleistungen und Lösungen für die Intralogistik. Mit einem Vertriebs- und Servicenetzwerk in mehr als 100 Ländern ist das Unternehmen in allen wichtigen Regionen der Welt vertreten. In Weilbach fertigt der Warenumschlagspezialist Gegengewichte für das umfangreiche Angebot an Gegengewichtsstaplern. Mit neuer Strahlanlage Optimierungspotenziale ausschöpfen Linde MH strebt kontinuierlich nach einer Verbesserung seiner Fertigungsprozesse. In enger Zusammenarbeit mit der Rösler Oberflächentechnik GmbH optimierte ein Projektteam den logistischen Materialfluss und die Flexibilität bei der Bearbeitung von unterschiedlichen Gabelstaplergegengewichten (kurz GGW). Mit der Vorgabe einer optimierten Flächennutzung, setzt die Fa. Rösler kompetent, mit einem maßgeschneiderten Konzept einer Hängebahn-Durchlaufstrahlanlage RHBD 22/27-F , neue Maßstäbe in der Gießereibranche. Vollautomatischer, fertigungsintegrierter Betrieb mit hoher Flexibilität Durch die neu strukturierten Prozessabläufe erfolgt eine optimierte Übergabe der unbearbeiteten Rohgussteile an einem gekennzeichneten Ablageort vor der Einlaufkabine. Mittels manueller Positionierung und Freigabe erfolgt der Teiletransport mit einem Power & Free-Fördersystem. Je nach Bauteiltyp werden spezifische Strahlparameter sowie auch Parameter des Fördersystems hinterlegt. Nur so ist zu gewährleisten, dass das GGW metallisch rein mit gleichmäßiger Oberflächen-Rauigkeit gesäubert wird, sowie eine haptisch gleichmäßig wirkende Strukturierung der Gussteiloberfläche, welche nach dem Lackieren noch deutlich den Gusscharakter erkennen lässt, wiederholbar wird. All diese Prozessparamater wurden mit einem dafür bestimmten, speziellen Strahlmittelbetriebsgemisch definiert. RHBD 22/27-F in Gießerei-Ausführung Am neuen Standort im Werk wurde die neue Strahlanlage nach den örtlichen Vorgaben realisiert. Auf engstem Raum und für die Wartung zugänglich, wurde die Strahlmittelsandrückführung unter der Strahlanlage ausgeführt. Der abfallende und angehäufte Formsand, welcher am Ablage- und Übergabeort der GGW anfällt, wurde ebenfalls zur Rückführung in die Strahlmittelaufbereitung integriert. Der Sand wird vor der Einlaufkabine der Querrutsche zugeführt. Diese befördert das Material auf die Sandübergaberinne, welche anschließend den zugeführten Sand der GGW und den Sand aus der Einlaufkabine auf die Rückführrinne unter der Einlaufkabine übergibt. Von der Rückführrinne findet eine Übergabe auf die zentrale Siebrinne der Strahlkabine statt. Am Auslauf der Strahlanlage fördert ein Flachförderboden Sand- und Strahlmittelreste ebenfalls zu der zentralen Siebrinne unter der Strahlkabine. Die Siebrinne scheidet dabei gröbere Sandknollen, Grate und metallische Flitter zuverlässig ab und führt diese einem gießereitechnischen Z-Förderband zu. Von der Siebrinne über Becherwerk wird das Strahlmittel-/Sandgemisch dem Separationssystem mit hohem Abscheidegrad zugeführt. Die zuverlässige Reinigungsleistung über einen zweistufigen Magnetseparator mit pneumatischer Nachsichtung gewährleistet einen störungsfreien Betrieb und reduziert den Verschleiß der Gesamtanlage. Nach der manuellen Positionierung des GGW am Teile-Transportwagen der Power & Free-Förderanlage werden die Rohgussteile durch die einzelnen Anlagenteile - Einlauf-, Strahl- und Auslaufgehäuse - getaktet. Neben der Taktzeitoptimierung durch eine 3-Kammer-Strahlanlage wurde zudem eine weitestgehende Minimierung von Strahlmittel-Sand und austretenden Staubverlusten in die direkte Hallenumgebung erreicht. Das eigentliche Herzstück der Anlage ist die Strahlkammer mit fünf angeordneten Strahlturbinen. Der Strahlraum, gefertigt aus verschleißfestem Hartmangan X120Mn12, ist zusätzlich mit 25 mm dicken, auswechselbaren, verschleißbeständigen Chromgussplatten ausgekleidet. Die gesamte Strahlanlage ist über ein großzügiges Wartungspodest mit Treppenaufstieg sehr wartungs- und bedienerfreundlich. Ziele erreicht Durch die neu konzipierte Hängebahn-Durchlaufstrahlanlage sind die vorgegebenen Ziele eines technisch und ökonomisch optimierten Gesamtprozesses Strahlen & Handling der Linde MH erreicht. Wiederholbare Qualitätsanforderungen der GGW-Bauteile durch neudefinierte Strahlparameter, Strahlbild- und Verschleißoptimierung ergeben schlussendlich eine Optimierung im Prozess der Strahltechnik sowie Effizienzsteigerungen durch das optimierte Strahl- und Materialflusskonzept im Werk.

Wet Blasting Equipment & Media, Part 4 – Internal Cleaning, Rebuilds Prolong Machine Lifetime

While highly effective in a number of applications and industries, wet blasting can be a messy process. Unlike dry shot blasting which produces dust, wet blasting generates a mix of media, dirt, and debris mixed with water mist. If this water/particle mix is not removed properly the machine itself may be soiled to the point that it cannot be used. Mist which escapes the machine can also cause health hazards to personnel and other equipment in the area. Rosler builds its wet blasting machines with usability and safety in mind, factoring in precautions and cleaning functions to prolong the machine’s use and ensuring a clean, safe work environment. Internal Cleaning Rinse systems flush out contaminants including dirt, broken down media, and oil from the blast cabinet. After each blast cycle the inside of the wet blast machine must be cleaned by completely rinsing it down with clean water. High-pressure spray nozzles are installed to rinse the wet blasting machine’s viewing window. During the blast cycle and as needed, high-pressure spray nozzles rinse off any dirt from the viewing window. Water mist from processing as well as the internal cleaning process is continuously removed from the blast cabinet by a suction fan equipped with a filter which removes contaminants from the water. Rebuilding Established Systems Blast machines are often a considerable investment for companies. When these highly specialized and high-investment pieces of equipment start to show signs of wear and underperformance, expert surface finishing companies such as Rosler can help prolong the life and effectiveness of your investment by repairing and rebuilding a machine instead of replacing it. Cost is often the biggest factor considered when rebuilding a blasting machine. Generally, rebuilds offer shorter turnaround times than buying a new machine. Rebuilds also come with the added benefit of not needing to integrate a new process since the process already includes a proven shot blasting process. The Rosler Way We have the experience and expertise to meet your wet blasting needs. Rosler partners with you to find a better way, the best machine, and the best finishing results. Contact us today to discuss your unique challenges. Previous posts in the Wet Blasting Equipment & Media series include: Part 1 – “Machines Range in Complexity, Uses.” Part 2 – “Technical Components Combine for Systematic Success.” Part 3 – “Maintain Slurry Concentrations for Finishing Consistency.” The final post will be: Part 5 – “Careful Media Selection, Additive Use Impact Results.” Sign up for enews alerts to be notified of new posts!