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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!

Millenia Technologies is the new sales and service partner of Rösler in India

With Millenia Technologies, the Rösler Oberflächentechnik has a new and strong partner for the Indian market at its side. Millenia already works for years in the field of surface treatment and has lots of experience in the finishing, cleaning and measuring of components to enhance surface textures. With the mass finishing and shot blasting solutions of Rösler, Millenia can perfectly complement their portfolio of bringing the most advanced surface technologies to different industries. We are looking forward to a good cooperation with Millenia Technologies and to serve the Indian market even better.

Automotive Manufacturer Partners with Rosler for Fast Processing, Long Wear Life

True to our “finding a better way…” motto, Rosler partnered with thyssenkrupp AG to create a continuous flow shot blasting operation for the fastest crankshaft forge shop in the world. World renowned for its drive trains, chassis, and automobile manufacturing equipment, the automotive division of thyssenkrupp AG significantly contributes to the technical progress and efficiency of motor vehicles. The thyssenkrupp Gerlach GmbH plant in Homburg, Germany, is a leading partner for the development of automobile engine components, offering a full-service package ranging from component design, prototype fabrication, and full-scale production. Developing a Solution To improve cost efficiency at its Homburg plant and to meet all customer requirements, thyssenkrupp AG installed its high-tech “production line 19” for forged crankshafts for engines with one to four cylinders in 2016. For this line, Rosler developed an innovative shot blast equipment concept known as the Rosler RKWS crankshaft shot blasting system . At the beginning of the manufacturing sequence, bar blanks are cut to length. They are then heated in an induction oven before being shaped in a 6,500-ton press. In the last step, the crankshafts undergo a blast cleaning process in a shot blast machine. Using a unique equipment concept for the final blast cleaning step, Rosler engineers created a system for handling different work piece sizes without time-consuming retooling of the work piece holders. This innovation helped reduce the cycle time to less than 10 seconds, which in turn allowed the manufacturing operation to be run in a continuous flow. The result of the comprehensive cooperation between thyssenkrupp AG, Rosler, and all the other partners created the fastest, most modern crankshaft forge shop in the world capable of producing a finished component for its customers every 7.5 seconds. Crankshaft after surface finishing Delivering Convenience & Longevity Our innovations go beyond world records to provide long-lasting value and dependability. The RKWS system was also designed for long life and easy maintenance. The three blast chambers and the work piece load/unload chamber are arranged in a circle around a rotary drive equipped with an asynchronous servo motor with an extremely high overload reserve. Blast media is accelerated and thrown by Rosler Gamma G blast turbines equipped with a unique Y-shaped throwing blades. Rather than being made of chilled iron castings typically used in conventional turbines, critical wear components of the turbines are made of forged tool steel. This results in a much longer uptime of the throwing blades whose curvature produces a much higher throwing speed than straight throwing blades. In addition, the symmetrical Y design allows the use of both blade sides. The combination of more wear resistant material and the blade geometry result in up to three times longer usable blade life. Another feature of the Gamma G turbines is their easy maintenance. Turning the blades around or exchanging them can be done from the top of the turbine housing without having to dismount the impeller, control cage, and the media inlet tube required with conventional turbines. The RKWS is equipped with 12 Gamma G turbines, each with an installed power of 22 kW. The turbines, evenly placed on the three blast chambers, are capable of throwing the large steel shot onto the entire surface area of the crankshafts with a speed of 80 meters per second. This results in a complete removal of forging scale and other surface contaminants. By utilizing highly wear resistant material for all components exposed to the large cast steel shot and the removed forging scale, the RKWS shot blast system’s external workings are protected from excessive wear. The three blast chambers are lined with wear resistant hardened steel. Media augers are made from special steel that is predominantly utilized in the mining industry. Technical characteristics of this material are its extreme toughness and its remarkable hardness of 600 Vickers providing it with a considerable structural strength. Planning Proactive Maintenance Thyssenkrupp AG’s “production line 19” processes the entirety of the company’s customer orders within 21 shifts per week, posing a considerable organizational challenge for the thyssenkrupp Gerlach GmbH maintenance department. In order to manage time for the equipment upkeep, the maintenance team utilizes a TBM (time-based maintenance) system. Within a pre-determined time span, a recurring time window is defined for all inspection and maintenance activities as well as any required repairs including the replacement of spare parts. The time management allows requisitioning all repair materials in advance and facilitates the effective assignment of the maintenance personnel at thyssenkrupp Gerlach GmbH in Homburg. Stocking Spare Parts Planning certainty for the entire manufacturing line along with consistently high product quality is a high priority at thyssenkrupp Gerlach GmbH. For this reason, essential wear and spare parts for all machines were determined jointly with the equipment suppliers and stocked on-site in Homburg. To define the specific requirements for the crankshaft shot blast machine, the customer relied on the experience of the Rosler service department. Based on the customer specifications, our service experts conducted a risk and wear analysis using an ultra-modern simulation of the blast media recycling process allowing them to determine the wear intensity for every single component. Based on the results of the analysis a comprehensive list of recommended spare parts was prepared including wear parts such as protective wear plates, etc. The Rosler Way Working with an experienced supplier is the best way to develop and maintain a shot blasting operation. From selecting the right type of machine for your needs to suggesting everyday actions to ensure repeatable results and extended uptime, Rosler develops lasting solutions. Contact us to learn how we can put our surface finishing expertise to work for you!

Rösler spendet 8.000 Euro an "Helfen macht Spaß"

Solidarität und Zusammenhalt bilden das Fundament, auf dem unser Unternehmen und alles, was wir tun, steht. Diese Solidarität und dieser Zusammenhalt sind es auch, die uns weiterhin gemeinsam durch diese herausfordernden Zeiten führen werden. Es hat in unserem Unternehmen eine lange Tradition, dass wir auf die üblichen Weihnachtsgeschenke an unsere Geschäftspartner und Kunden verzichten und stattdessen das Hilfsprojekt „Helfen macht Spaß“ unterstützen, das vorrangig karitative Projekte in unserer Obermain-Region fördert. Vielen herzlichen Dank an alle Lieferanten, die unserem Aufruf zur Unterstützung der Aktion "Helfen macht Spaß" des Obermain-Tagblattes gefolgt sind. Aufgestockt durch Rösler kamen so 8.000 EUR zusammen. Diese Spende geht direkt an hilfsbedürftige Menschen in unserer Region. So werden Weihnachtsgeschenke an Bedürftige verteilt, Finanzspritzen für Familien in Not gegeben oder finanzschwache Alleinerziehende können sich über unbürokratische Hilfe freuen. Stephan Rösler brachte es auf den Punkt, warum er die Leseraktion auch in diesem Jahr gerne wieder unterstützt hat: „Menschen aus der Heimat in Not sinnvoll, unbürokratisch und effizient zu helfen, dafür schätze ich ‚Helfen macht Spaß‘“, erklärte er.

Tumble belt blast machine for coating preparation

Blast cleaning of springs prior to coating Shot blasting is the most common pre-treatment technology to prepare the surface of technical springs for subsequent coating operations. In a newly established manufacturing line for compression springs this cleaning operation takes place in a Rösler tumble belt blast machine. Within short cycle times the custom-engineered RMBC 4.2-HD produces surfaces that are perfectly prepared for the subsequent coating operation. Oil carried into the shot blast process, is neutralized and, through the media cleaning system, separated from the blast media. The Baumann Springs Ltd., located in Ermenswil, Switzerland, is a global leader in the production of springs and all kinds of stampings. This family-owned company was founded in 1886 and ever since has been managed by the family, today in the fifth generation. Baumann Springs is specialized in the development and production of custom-engineered products with tight dimensional tolerances and high demands for process stability in the automobile industry, medical engineering and other markets. The products are manufactured in 11 plants in Europe, Asia and North-America. Shot blasting solution for a new production line In 2021 the plant in Stare Mesto in the Czech Republic established a new production line for different types of long compression springs made from spring steel EN 10270-2. For cleaning and texturing (roughening) the surface of the springs prior to coating, the company purchased a tumble belt blast machine, model RMBC 4.2-HD, from Rösler . Claudio Hertig, project manager global operations at Baumann Springs, explains: „For this challenging task we had discussions with several equipment manufacturers and requested quotes from three of the suppliers“. “The Rösler solution impressed us not only because of the design of the equipment but also its functionality. Another positive factor was the sturdy machine construction. To familiarize myself with the suppliers, I visited all three companies and prepared a detailed technical comparison. Last-but-not-least, our good experience with Rösler equipment already running at some of our facilities and the global presence of the company, also played a role in our decision for Rösler”, continues Mr. Hertig. Equipped for short cycle times and clean results The RMBC 4.2-HD was painted per customer specifications and is equipped with special technical features. It allows the blast cleaning of complete batches of loosely tumbling compression springs with batch weights of up to 1,000 kg. Two Gamma 300G turbines , each equipped with a power of 11 kW, ensure a high shot blast intensity. These high performance turbines, developed by Rösler, are equipped with curved throwing blades in “Y” design. Compared to conventional turbines the specially calculated blade curvature generates very high media throwing speeds resulting in an up to 20% higher blast performance and, consequently, shorter cycle times. All this is achieved with a lower energy consumption. Moreover, the special “Y” design of the throwing blades allows the use of both blade sides. This practically doubles the usable life of the throwing blades. A quick-change system permits a quick blade change without the need for dismounting the turbine from its housing. The blast process is further intensified and accelerated by the integrated blast media deflectors. These special compressed air nozzles are causing an additional blast media movement. The automatic blast media flow control allows not only the monitoring but also the precise adjustment of the media flow to the respective work pieces. The media replenishment takes also place fully automatically. An additional automatic dosing system allows the application of a powder cleaning compound in the blast chamber to catch and discharge any oil that may be carried into the shot blast machine by the work pieces. It should be noted that the powder compound does not affect the functionality of the blast media: In the air wash separator of the media cleaning system the powder is completely separated from the blast media. Since the machine was also intended for stripping the coating buildup from the work piece carriers used for the coating operation, the dry dust collector is equipped with explosion protection features. In order to minimize machine downtimes due to wear, the inside of the blast chamber is lined with easily replaceable 6 mm thick highly wear-resistant manganese plates. The left and right side of the media discharge opening of the turbines is equipped with additional wear plates. These bundle the media stream and prevent this section of the blast chamber to be attacked by the blast media. Finally, the barrel heads, also made from manganese steel, are equipped with a PU coating providing an additional wear protection in the primary blast zone. This helps to further extend the equipment uptime. Claudio Hertig concludes: „The comprehensive experience and know-how of Rösler with the production of such machines is an invaluable advantage that helps improve the overall efficiency of the equipment. In addition, the global Rösler technical service allows us to work in other plants with the same processes and machinery and have them maintained by local Rösler service engineers”.

Mass Finishing Process Water, Part 2 – Maintain Adequate Drainage to Protect Your System

Numerous functions and calibrations factor into developing a precise and stable mass finishing process. From media and compounds to work piece characteristics and processing times, successful finishing requires each process aspect to be carefully monitored and evaluated. When it comes to process water flow rates, poor drainage from the machine can cause quality control issues as well as equipment damage and costly downtime. While simple in their function, drains play an integral role in regulating the flow of process water out of the machine. With the exception of intentional “flooding” of the process bowl for sharp work pieces, the same amount of compound and water entering the machine must be flushed out again. Otherwise, contaminants in the form of dirt, media, metal fines, and, frequently, oil will accumulate in the process water. Since this buildup can cause the finishing process to deteriorate and even collapse, mass finishing machines must have sufficient drainage! With more than 80 years of experience, Rosler can expertly design mass finishing technology and troubleshoot issues to protect your system for the life of the machine. Machine Features Most mass finishing machines, including rotary and tub vibrators and drag‐ , plunge‐ , and surf‐finishers have special drainage screens built into their work bowls. High-energy centrifugal disc finishing machines differ since the “dirty” process water is evacuated through the gap between spinner and work bowl. Drain types used in rotary vibrators. Made from plastic such as polyurethane or stainless steel material, these drains must allow process water and media debris to be flushed from the system while retaining usable media mix and the work pieces. Machines utilizing small media, including steel media for ball burnishing or pressure deburring , always require more drains since small media has a much higher water retention rate than large media. Regardless of the media size, drains can be easily plugged with media debris, flashes from die castings, small metal pieces, etc., and it is essential to make sure that the drains are regularly inspected and cleaned. Drain for undersized media seperation in the work bowl. Manual Evaluation Taking action to prevent process failure, machine damage, and costly repairs and downtime will improve process results and machine longevity. To ensure proper process water drainage: Make sure that the work bowl of your mass finishing machine contains enough drains. If additional drains are needed, they can be easily installed while the work bowl is being relined. Alternatively, a suction pump can be installed for faster evacuation of the process water, if needed. Regularly inspect the machine drains and make sure that they are in good condition, functioning properly, and removing debris appropriately. Install drains with bigger or differently shaped holes if plugging occurs. The Rosler Way Working with an experienced supplier is the best way to develop and maintain a mass finishing operation. From selecting the right type of machine for your needs to suggesting everyday actions to ensure adequate drainage, Rosler develops lasting solutions. Contact us to learn how we can put our surface finishing expertise to work for you! The complete Mass Finishing Process Water Series includes: Part 1 – Understand When to Balance Flow or Flood the Process Bowl . Part 2 – Maintain Adequate Drainage to Protect Your System .

GPAINNOVA Installs a DLyte PRO500, the Most Advanced Dry Electropolishing Machine, at Rösler’s Customer Experience Center

GPAINNOVA, one of the leading groups in surface finishing technologies, has recently installed its DLyte PRO500 at Rösler’s Customer Experience Center in Untermerzbach (Germany). With more than 80 years of experience, Rösler is the leading group in the field of surface finishing and offers the world's most comprehensive portfolio of mass finishing and shot blasting equipment and related consumables. With this acquisition — the most advanced, powerful, and versatile dry electropolishing machine on the market— Rösler completes the range of DLyte machinery available at its headquarter in Germany. The DLyte PRO500 will help Rösler, the exclusive sales partner for GPAINNOVA in Germany, to further expand its range of polishing solutions for industrial applications, both for conventionally and additively manufactured parts. The DLyte PRO500 is designed to treat large batches and bigger parts with complex geometries requiring high quality surface finishing. For some specific applications, a combined process consisting of mass finishing equipment and Dry Lyte polishing technology offers an outstanding and unique surface quality in a highly efficient manner .

820 Jahre Betriebszugehörigkeit: Die Rösler Oberflächentechnik GmbH ehrt 67 langjährige Mitarbeiterinnen und Mitarbeiter

Die Rösler Oberflächentechnik GmbH freute sich auch in diesem Jahr wieder 67 Mitarbeiterinnen und Mitarbeiter für deren insgesamt 820 Jahre Treue und Loyalität zu ehren. Allerdings mussten, wie bereits im Vorjahr, die Feierlichkeiten coronabedingt in kleinem Rahmen unter strenger Einhaltung der Hygienevorschriften stattfinden. Die traditionelle Ehrungsfeier der Jubilare sowie die Verabschiedung treuer Mitarbeiterinnen und Mitarbeiter in den Ruhestand sollte in diesem Jahr erstmalig in dem neuen und modernen Betriebsrestaurant der Rösler Oberflächentechnik GmbH am Standort Memmelsdorf stattfinden. Doch auch in 2021 konnte die Feierlichkeit aufgrund der Corona-Pandemie leider nicht in dem ursprünglich geplanten Rahmen abgehalten werden. Um den Jubilaren trotzdem die verdiente, persönliche Wertschätzung gegenüberzubringen, fanden die Ehrungen in kleinen Gruppen durch die entsprechenden Führungskräfte unter Wahrung der erforderlichen Hygieneregeln statt. In diesem Zusammenhang dankten die jeweiligen Führungskräfte im Namen der Rösler Oberflächentechnik GmbH ihren langjährigen Mitarbeiterinnen und Mitarbeitern für deren Loyalität und Engagement. Die Rösler Oberflächentechnik GmbH gratuliert … zum 40-jährigen Betriebsjubiläum: im Werk Memmelsdorf: Harald Wendelmuth und Helmut Lutter sowie Gertrud Rädlein aus dem Werk in Hausen. … zum 25-jährigen Betriebsjubiläum: Roland Schaad, Michael Striebe und Edmund Hübner – alle tätig im Werk Memmelsdorf – sowie Bernd Sauerteig im Werk Hausen. … zum 10-jährigen Betriebsjubiläum: im Werk Memmelsdorf: Daniel Bahls, Gerhard Bauer, Michael Berwind, Jens Beugnies, Marcus Breitfelder, Patrick Diez, Stephan Dohles, Ivan Drescher, Thilo Friedel, Florian Gries, Stefan Gründel, Marco Habermann, Stephan Hacker, Adrian Häfner, Viktor Heinrich, Herwig Heiser, Angela Herr, Simone Jäger, Woldemar Jung, Stefan Kalb, Manuel Kambach, Daniel Keim, Tom Kollacks, Manfred Kohmann, Tobias Kurzendörfer, Andreas Lamm, Johannes Leicht, Denis Leidner, Stefan Mantey, Iris Martin, Sebastian Martin, Katharina Meixner-Pelkner, Andreas Popp, Marcus Roth, Benedikt Reubel, Patrick Rösler, Lisa Schad, Anna Schlawne, Christian Schmidt, Astrid Schwappach, Oleg Strauch, Peter Strohschein, Benjamin Sülzle, Oxana Walinger, Rebecca Walther, Dimitri Wander, Bernhard Waschkowski, Dimitri Winterholler, Christoph Wunner und Thomas Zimmermann. im Werk Hausen: Vladimir Bauer, Steffen Beyer, Fabian Heer, Alexandra Janson, Andreas Kästner, Bernd Landvogt, Mario Nüßlein, Sabine Precklein, Viktor Schell und Marion Zeller. Nach langjährigem verdienstvollen Einsatz wurden Detlef Bauer, Josef Bornschlegel, Albin Dorsch, Günter Elflein, Adelgunde Fischer, Ralf Gutmann, Uwe Hein, Gerd Leipold, Uwe Michael, Josef Schnapp, Siegfried Schrenker sowie Hartmut Tremel in den Ruhestand verabschiedet. Rösler stellt die Weichen für eine erfolgreiche Zukunft In seinem traditionellen Weihnachtsgruß bedankte sich Stephan Rösler, Geschäftsführender Gesellschafter der Rösler Oberflächentechnik GmbH, bei allen Mitarbeiterinnen und Mitarbeitern für deren tatkräftige Unterstützung und Loyalität in einem Jahr, welches aufgrund der Corona-Pandemie und der damit verbunden wirtschaftlichen Situation strukturelle Anpassungen im Unternehmen erforderlich machte. „Doch nur wer sich ändernden Rahmenbedingungen nicht verschließt und entsprechend reagiert, kann langfristig und nachhaltig erfolgreich sein“, so die Maxime von Stephan Rösler. Dass die getroffenen Maßnahmen erste Wirkung zeigen, beweist eine deutlich verbesserte Auftragslage, wenn auch nicht auf Vorkrisenniveau. Zudem investierte das Unternehmen auch in Krisenzeiten wieder in wichtige Zukunftsthemen wie z. B. die Digitalisierung und Automation, sowohl in Form der angebotenen Produkte als auch im Unternehmen selbst. Als Teil des produzierenden Gewerbes ist sich die Firma Rösler aber auch seiner gesellschaftlichen Verantwortung gegenüber dem Thema Nachhaltigkeit bewusst und ist deshalb seit kurzem Teil der VEA-Initiative „Klimafreundlicher Mittelstand“. Darüber hinaus ist das Unternehmen nun bei der CDP gelistet, bei der es sich um eine gemeinnützige Organisation handelt, die Unternehmen und Regierungen zur Nachhaltigkeit anhält und die weltweit führende Plattform zur Offenlegung von Umweltdaten betreibt. Die insgesamt getroffenen Maßnahmen lassen den Geschäftsführenden Gesellschafter der Rösler Oberflächentechnik GmbH optimistisch in die Zukunft blicken.

Wet Blasting Equipment & Media, Part 3 – Maintain Slurry Concentration for Finishing Consistency

Wet blasting propels a mixture of media and process water at the surface of a work piece to provide cosmetic (anti-glare) finishes, surface smoothing , deburring , de-powdering, decontaminating, and cleaning after casting, welding, machining, and additive manufacturing . Useful in a variety of industries , this specialized form of shot blasting relies heavily on the media and water mix known as wet blasting slurry to work in tandem with the machinery in order to deliver the desired finishing results. Rosler has extensive experience developing wet blasting systems as well as providing guidance on slurry concentrations and supplying the necessary consumables . Slurry Characteristics Wet blast schematic The slurry is created in a tank housed within the blast chamber by mixing water and an abrasive media. A special pump delivers the slurry to the blast gun where it is then propelled onto the work surface using compressed air. High-speed impact of the slurry on the surface of the work piece creates the desired blasting effect, be it cleaning, coating preparation, cosmetic surface texturing, or peening . Wet blasting in process The concentration of abrasive media in the slurry usually amounts to 10-40% by volume, for example, 20% media and 80% water, etc. Establishing the ideal concentration may require extensive processing trials initially or if the work pieces and their original condition change. In these cases, contact the machine manufacturer for guidance. Controlling Slurry Concentrations Regular and gradual slurry loss is expected even in a well-calibrated finishing operation. During the blast process the media wears by becoming smaller or fracturing. These smaller and irregular pieces must be removed from the system. To make up for this loss and removal of undersized media, new media must be added. Maintaining a very tight tolerance range of 1-2% in the prescribed slurry concentration is required to achieve consistent results. For smaller systems, maintaining slurry concentration can be done by visual inspection of the media-to-water ratio in the graduated viewing glass of the concentration measurement unit and manually adding media as needed. In larger blast systems, the slurry concentration is controlled automatically with an ultrasonic level sensor, a weighing system, or continuous density measurement. Adding media to the desired concentration level can be done manually or through an automated, PLC-controlled media adder. Manual slurry concentration measurement unit The Rosler Way Rosler has more than 80 years of experience in shot blasting. Whatever your wet blasting challenges are, we are confident that we can deliver a solution. Contact us to discuss your needs today! 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.” Upcoming posts will include: Part 4 – “Internal Cleaning, Rebuilds Prolong Machine Lifetime.” Part 5 – “Careful Media Selection, Additive Use Impact Results.” Sign up for enews alerts to be notified of new posts!

Innovative consumables for mass finishing operations

Simple steps to improve finishing results, sustainability and efficiency When it comes to achieving the required quality of products by surface refinement, the mass finishing technology can be used for a broad range of different finishing tasks. With its comprehensive research & development activities the Rösler Oberflächentechnik GmbH continues to generate new technical highlights not only for the machine technology but also for the respective mass finishing consumables. Three recently introduced products make it possible to significantly improve the finishing results, the process consistency, the cost efficiency and sustainability of mass finishing operations. At the same time, they open the door for new applications, for example, the finishing of complex, cup-shaped work pieces. The mass finishing technology can handle all kinds of surface finishing tasks ranging from the simple deburring/edge radiusing and surface grinding to high gloss polishing of mass-produced bulk goods and single components. It can even create special effects on the surface of the work pieces. Of course, like any other industrial processes, mass finishing operations must comply with all kinds of requirements such as high quality standards, process stability, work piece traceability and cost-efficiency. More recently optimal resource utilization and sustainability have become a focal point in numerous industries. And finally, the rapidly growing automatization and digitization of manufacturing operations also calls for specially adapted solutions for mass finishing operations. For decades the Rösler Oberflächentechnik GmbH has met these challenges with comprehensive research and development in the equipment sector as well as in the fields of process and automation technology and consumables. In this context a big advantage is that Rösler is producing all its consumables in-house. Rüdiger Böhm, global R & D manager at Rösler, explains: „We study the technical trends and requirements in numerous industries and markets extensively. Our findings are then systematically utilized for the development of innovative products to provide a significant incremental value to our customers and to expand the application range for the mass finishing technology”. MultiShape – a unique media shape that makes the impossible possible Such an innovation is the new MultiShape ceramic media. Compared to all other products currently available in the market, this media has a patented shape without any flat, parallel surface areas. On the one hand this unique design prevents media lodging in the work pieces, which can occur particularly in case of complex work pieces. Such lodged media can severely affect the finishing process and must frequently be removed by hand. On the other hand, the shape with its rounded surface areas allows the surface refinement of work pieces, which to-date could not be handled by mass finishing at all or only with very complicated operational setups. This includes components with difficult-to-reach surface areas like tight radii, undercuts, notches and slits, which can frequently be found in stamped and bent components. The unusual ceramic media also allows the effective and homogeneous finishing of external and internal surface areas on tube segments and cup-shaped components like housings and deep drawn parts. Compared to traditional ceramic media, the new product is also characterized by a faster and more dynamic motion of the work piece/media mix and a higher material removal rate. This results in up to 10 % shorter finishing times. Therefore, the new media represents a significant contribution towards higher productivity and cost-efficiency. Another important attribute of the MultiShape media are its uniform wear characteristics. This excellent shape retention feature allows a longer media use, which is positively affecting the operating costs. The grinding intensity can be adjusted to the respective finishing application through different ceramic compositions. Mass finishing without foaming – increased process stability, efficiency and sustainability Unwanted foam is a common phenomenon in mass finishing processes with plastic media, even with foam-reduced media versions. Foaming can be problematic because, acting as a buffer between the work pieces and media, it reduces the grinding performance and material removal rate. This can diminish the process stability, and the processing aim can frequently no longer be achieved within the defined cycle time. Moreover, the foam containing metal and media fines contaminates the surface of the finished work pieces. The foam also causes a deterioration of the process water cleanliness, requiring a higher compound dosing rate and forcing the user to replace the process water more frequently. Last-but-not-least, foam discharged from the mass finishing machine contaminates the working environment. In the past the users tried to control the foaming by adding special chemical compounds. But this was not very successful, caused additional costs and reduced the process sustainability. With its non-foaming plastic media, the so-called “N” version, the R & D department at Rösler has now developed a better solution. Christian Höhn, head of the technology management at Rösler, explains: ”Prior to introducing the product in the market we conducted extensive field trials with special pilot users. The trials proved convincingly that the non-foaming plastic media has the same grinding characteristics and performance as the standard product”. The trials also demonstrated that with the newly developed media the mass finishing processes are running much more stable, and the required results are achieved in shorter cycle times. This positive effect regarding cost-efficiency and sustainability is augmented by a longer usable life of the media and process water and a reduced compound usage. ”Because of the disruptive foaming many users had been using ceramic media, even though this was not the best option. For these users the non-foaming plastic media version is a great opportunity to optimize their finishing processes”, concludes Christian Höhn. All plastic media in the comprehensive Rösler portfolio are available in the non-foaming “N” version. Dust-free drying with organic drying media The third new development in the consumables sector in 2021 allows a significant reduction of the dust occurring during drying processes utilizing organic drying media such as maizorb. Even in small quantities the liquid, easily dispensable, Anti-Dust additive significantly reduces the formation of dust. Depending on the operating times and work pieces the additive can be manually added or dosed fully automatically. The Anti-Dust additive is employed in drying operations for metal and plastic components, whenever organic drying media is used. Without negatively impacting the drying performance it guarantees absolutely spot-free surface finishes. At the same time, dust residues on the finished work pieces and the surrounding area are minimized. This also represents a huge step towards a clean, low-dust working environment. Rainer Schindhelm, division manager of the consumables production, explains: „Because it is purely organic and complies with the prevailing food standards, the Anti-Dust additive also represents a significant contribution towards a cleaner environment”. Increasing the productivity of the mass finishing technology, improving overall sustainability and reducing CO2 emissions; these are the main goals of the development work at Rösler in the year 2022. Various solutions from the sectors equipment technology and consumables are already being tested at various customers.