When a casting is produced, by-products are
generated. Small pieces originating from spills, gates, runners, and risers are
returned to the casting process as recycling material. To ensure a consistently
high overall quality of the raw material, it is essential that this recycling
material is perfectly clean without any sand, casting shell, or other residues
on the surface.
Subjecting these by-products to a blast cleaning process from Rosler Metal Finishing before they are re-melted offers many advantages. Besides the resource-saving use of raw materials, the effective cleaning of the recycling material increases the uptime of the smelting furnaces by significantly reducing the amount of unwanted slag.
Components made from steel, nodular cast iron, and
grey iron can be processed by mass finishing equipment.
To increase a company’s overall resource
efficiency, the spills, gates, runners, and risers are often separated from the
castings at the shakeout station and recycled into the casting process. Prior
to re-melting, the contaminants consisting of residual sand and casting scale
must be completely removed from the recycling material.
One key factor in selecting the best shot blasting
machine for your purposes is to consider the cleanliness produced by various
models. Expert shot blasting companies can specially adapt equipment to your
Using special heat-resistant materials for various
components including transport belts, plastic components, and electronic
components allows continuous operation without having to wait for the recycling
material to cool down. Special vents in the blasting drum dissipate heat
carried into the drum with recycling material and prevent excessive heat
Large inspection platforms accessible by stairs is
also an added feature of many shot blasting machines used for forge and foundry
processes. For quick mounting/dismounting of the turbine and blasting drum, machines
can be equipped with dedicated gantry or jib cranes. Both ensure easy and quick
maintenance and improve the overall uptime of the blast machine
Efficiency and Uptime
Additional turbine throwing blades and the use of
wear lining on blades made from solid tool steel can increase the productivity
of turbine blades while improving blade longevity. The shape of individual
blades can also increase productivity.
Rosler’s Gamma high-performance turbines feature throwing blades curved in the special “Y” design. Compared to conventional blast turbines the curved blades produce an up to 20 percent higher blast performance with, at the same time, lower energy consumption. Since both blade sides can be utilized, a simple turn of the blades practically doubles the expected life of the throwing blades. This is easily done with the help of a retaining bolt system and does not require disassembling the turbine.
0ur 400 Gamma G blades can be turned in less than 4 minutes. See for yourself in a video demonstration below or take a virtual, 360-degree tour.
Systems for transporting, collecting, weighing,
and processing recycling materials can automate systems.
Conveyor belts can be added to transport recycling
material from the shakeout station to an impact crusher where the spills,
gates, runners, and risers are crushed into smaller pieces. These can then be
transferred to the fully automatic multi-tumbler loading station equipped with
weighing cells. Once the preset weight in the loading station is reached, the
conveyor belt stops and the loading system transfers recycled material into the
blasting drum. Upon completion of the loading cycle, the system returns to its
Alternatively, the loading system can receive the
work pieces in a variety of different part bins as part of a double-acting
During the shot blast cycle, the drum is
hermetically sealed with a lid. This prevents any blast media from spilling into
the immediate environment. While the drum rotates, the turbine throws blast
media onto the recycling material. The rotational speed of the drum and the
turbine can be easily adjusted with frequency inverters.
In combination with the multi-tumbling movement of
the recycling material in the drum, blast media throwing quantity adapted to
the batch size ensures that all pieces are equally exposed for complete and
reliable removal of contaminants. Resulting scale and sand are discharged from
the drum through a dust collector.
Blast media is removed from the drum through custom-engineered
screen inserts. Depending on the batch size and the density of the recycling
material, the processing time can vary from a few to 10 minutes. At the
conclusion of the blasting cycle the drum tilts into unload position. The shot
blasted material is dumped onto a vibratory conveyor for transportation.
The Rosler Way
The shot blasting process not only contributes to
a greatly improved quality of the castings, but because practically no residual
contaminants in the form of scale and sand are carried back into the casting
process, less slag is formed in the smelting furnaces. This reduces wear on the
refractory furnace lining and energy consumption while improving uptime.
Whatever process you have, Rosler Metal Finishing can learn about your challenges to develop and deliver a solution for forge shot blasting. Contact us today to discuss your unique challenges.
The complete Forge & Foundry Series includes:
- Part 1 – Shot Blasting Systems.
- Part 2 – Efficient Recycling.
- Part 3 – Shot Blasting & Sand Castings.
- Part 4 – Selecting a Shot Blasting Machine for Sand Castings.
- Part 5 – Cleaning Features & Dust Precautions for Sand Castings.
- Part 6 – Selecting a Shot Blasting Machine for Die Castings.
- Part 7 – Selecting a Shot Blasting Machine for Forgings, Non-Sand Castings, and Powdered Metal Components.
- Part 8 – Frequently Used Shot Blasting Machines for Sand Castings.
- Part 9 – Frequently Used Shot Blasting Machines for Forgings, Non-Sand Castings, and Powdered Metal Components.
- Part 10 – Shot Blasting Machines Commonly Used for Die Castings.
- Part 11 – Top Mass Finishing machines for Cleaning Die Castings
- Part 12 – Media and Compound Selection, Effluent Handling Drive Success
Sign up for enews alerts to be notified of all Rosler blog posts!