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Rösler Smart Solutions: Digital management of the process water parameters – Better process understanding improves mass finishing results

In his very first diesel engine Rudolf Diesel used already springs from the Siegmund Scherdel wire drawing company founded in 1889. Since then the company has evolved into a globally active operation that deals with forming, assembly and joining technologies as well as surface treatment. In addition, the company is also active in the manufacture of tooling and equipment. With 32 facilities around the world Scherdel actively supports its customers with services that range from initial briefings to volume production. The result are premium products that are not only used in the automotive industry but also in medical and electrical engineering as well as power generation. The products include stamped and bent parts, lock washers and components for electric vehicles. The latter are produced at the Scherdel Waldershof GmbH & Co. KG in Waldershof, Bavaria. The components made from different steel alloys, stainless steel and non-ferrous metals frequently receive their final surface finish in mass finishing operations. Besides the basic finishing tasks like deburring and edge radiusing, clean surfaces with a high degree of cleanliness are an important requirement. Clean surfaces are essential for conducting a proper optical quality control. In this context the quality of the process water plays a key role. Process water cleaning and recycling – for complex mass finishing applications At Scherdel Waldershof the process water from the mass finishing operation is cleaned and recycled with a semi-automatic centrifuge. However, to date the process water quality was only controlled by a daily check of the compound concentration. And this was usually done by different people who had little understanding and knowledge of the intricacies of the process water cleaning and recycling operation. „The process water gets contaminated by oil from the stamped & bent parts, belt lubricants and metal and media fines. On the one hand this increases the conductivity, which can cause faulty readings during the optical controls. On the other hand, the guidelines regarding particle size and quantities were not always followed. All this resulted in costly rework and even scrap parts“, explains Tobias König, department manager for mass finishing & cleaning at Scherdel Waldershof. Digital process water management results in transparency and generates knowhow When Rösler suggested to him to test the digital process water management system “Advanced” from Rösler Smart Solutions as a pilot user, the department manager immediately agreed. This new software package for semi-automatic and fully automatic centrifuges allows the user-friendly monitoring, recording and evaluation of all essential process parameters. These are: The compound concentration (measured by titration or refraction index – BRIX), pH value, conductivity, water hardness, microbiological contamination by bacteria, yeast and fungi, chloride content, COD value (chemical oxygen demand), BIT content (biocides in the process water), appearance and smell. Depending on the particular requirements for a given mass finishing process, the respective process parameters can be individually selected. In the “Advanced” version of the digital system the water samples are manually collected and analyzed with suitable measuring equipment that can be supplied by Rösler with the software package. The determined values are also entered manually. Based on the entered data the algorithm in the software develops recommendations for immediate corrective actions so that deviations from the specified values for the respective process parameters can be corrected and, thus, ensure process stability. Besides the recommendations for immediate corrective action the software also provides information that explains the adverse effects on the work piece surface, if the various parameter deviations are not quickly corrected. Since all data are recorded, they can be retrieved and displayed in the form of tables and time charts. This helps prevent costly downtimes by unplanned process water changes and allows to schedule such changes for time periods when they are less disruptive. „When Rösler presented the digital process water management system, we immediately recognized its potential for more transparency and a higher process stability. In addition, we realized that the recommended corrective actions along with the respective background information can be a tremendous educational tool that helps to increase the process knowledge of our employees“, concludes Tobias König. Increased process stability and improved finishing quality Scherdel Waldershof uses the digital process water management system with a semi-automatic Rösler centrifuge, model Z 800. This centrifuge cleans and recycles the process water from a Rösler mass finishing vibrator (model R 620) running in 3 shifts. The system controls the compound concentration and the pH value once per shift. A conductivity measurement takes place once per week. The microbiological contamination is checked whenever required. For example, this is the case, when the regularly monitored appearance and smell of the process water indicate that there might be a problem. The department manager explains: „The measurement and recording of the parameter values is easy and simple. We need about the same time for measuring and recording the compound concentration and the pH value as before.” He continues: „However, today we automatically receive an easy-to-read evaluation and a list of corrective actions that can be immediately implemented. This is a valuable tool to keep the process water stable and maintain a consistently high part quality. We have seen a reduction of rework and scrap parts by up to 50 %.“ The digital system issues not only recommendations for corrective actions when the parameters deviate from their rated values. Similar actions are proposed in case of events affecting the part quality and downstream manufacturing operations like corrosion, excessive foaming during the mass finishing process and insufficient cleanliness of the work pieces. To eliminate such problems the digital system issues detailed background explanations along with the recommended corrective actions. Tobias König concludes: „Most of the employees in my department have no special knowledge regarding mass finishing and handling of the process water. However, with the recommended corrective actions they not only learn what needs to be done, but they also acquire valuable process knowledge. This helps them understanding the relationship between the process water quality and the quality of the finished work pieces.“

Testing & Expertise Overcome Shot Blasting Challenges

For nearly a decade, Sales Representative and Interim Product Manager of Turbine Blast Equipment Zack Murray has been one of Rosler’s top shot blasting experts. Working with customers and our global Customer Experience Centers , he helps develop and test surface finishing machines and media in addition to dialing in specific process parameters. At times, adhering to the Rosler motto and guiding principle of “finding a better way…” can be difficult and complicated. Luckily, Murray and the entire Rosler team are committed to delivering world-class surface finishing equipment, consumables, and service in a variety of industries . In this post, Murray shares the most challenging issue he has tackled at Rosler and how the team developed a solution. The Problem A customer contacted Rosler for help in processing relatively large magnesium automotive parts. Considering the need for high throughput speeds in combination with the size of the parts, Murray knew a turbine blast machine would be the best option. Shot blasting turbine “In turn, the indication of a turbine blast machine meant that we were limited to metallic blast media,” Murray said, “as these machines are not typically suitable for mineral-based blast media such as aluminum oxide or glass beads. “Magnesium is a tricky material to blast in a turbine machine since it is prone to sparking with most metallic media. In addition to the fact that magnesium dust is highly flammable and combustible, we needed to avoid a potential recipe for disaster.” The process had to safely and efficiently deliver deburring and edge radiusing while minimizing the potential for sparking. The Solution Understanding that a relatively soft metallic media was required for safety and effectiveness, the team was left with the choice of aluminum or zinc blast media. Testing both media types demonstrated that results from the aluminum media most closely aligned with the customer’s desired process results. “Unfortunately, aluminum dust is also highly flammable and combustible,” Murray said. “The combination of the magnesium and aluminum dust was potentially dangerous enough to warrant an St3 Dust Hazard rating, which is the most severe rating, indicating a very high potential for fire and/or explosion. “Since the customer was not at a point in their product development cycle where they could get a dust hazard analysis performed as a result of part availability, we had to assume that the dust would be rated at St3.” As such, a wet dust collector with an anti-oxidizing compound dosing system was suggested for the customer with the further recommendation that the dust collector be installed outside, away from areas that commonly see human traffic, and that exhaust air was absolutely not allowed to feed back into the building. Rosler RF 550 NS including sludge drag conveyor and high-efficiency design to reduce residual dust The Rosler Way With more than 80 years of experience and a portfolio containing more than 15,000 equipment and consumable products, solving challenges is what we do at Rosler. Testing for safety and efficiency is an important step in achieving a stable and repeatable surface finishing process. Contact us today to request free test trials in one of our global Customer Experience Centers and allow us to develop a solution for your unique challenges!

Blade Technology: Straight vs. Curved Blades Explained

As an expert in the shot blasting industry, Rosler knows about blade technology. All shot blasting machines require blades to propel media towards workpieces. While both straight and curved blades are used, each type offers advantages and disadvantages. What are the Differences? Straight blades are, as the name suggests, blades that do not have curvature when viewed from the side and do not possess tangential curvature with respect to the turbine. Curved blades are blades that have some degree of curvature when viewed from the side. As the newer design, curved blades are generally better than straight blades, but they also have some drawbacks related to longevity, maintenance, and cost of ownership. Wear Rates Historically, the largest disadvantage of the curved blade design is that the blade will wear at a disproportionate rate along the length of the curvature, meaning that the curved blade design would wear through quicker than straight blade design. Modern technology has allowed the industry to overcome this particular flaw through the careful selection of curvature angle of the blade based on blade material properties to the point that curved blades now have similar usable lives to straight blades. Change Out Times A further disadvantage that has historically plagued the curved blade design is that the shape of the blades and fixturing take longer to change out than straight blades. The Rosler Gamma G turbine with forged metal blades overcomes this issue through the use of a retaining pin allowing for rapid blade change outs . This problem still currently persists for hard metal blade designs. Cost The final disadvantage is that curved blades tend to be more expensive than the straight blade designs, depending on the blade material. For cast and forged blades, the price difference is relatively small; however, for hard metal machined blades, the cost difference can be quite significant. Advantages Despite the disadvantages, curved blades also offer advantages over traditional straight blades. The largest advantage that the curved blades offer over straight blades of equivalent size is that the curved blades have a greater radial component to their velocities while maintaining an equivalent tangential component. This provides a higher throwing speed of the blades on the media (at equivalent turbine rotational velocities and equivalent turbine diameter) and therefore greater impact energy being transferred to the workpiece, allowing for the removal of more severe contaminants. Alternatively, if greater impact energy is not needed, the turbine’s rotational velocity can be controlled via a variable frequency drive to slow the turbine down which, in turn, provides a greater media throughput at equivalent media throwing speeds when compared against a straight blade turbine. Curved blade designs function at their best when the parts have very difficult finishing requirements or when greater part throughput is necessary. Orientations Curved blades have two types of orientation that can be used: a γ (The Greek letter gamma) shape and a C shape. The C shape has a greater curvature angle, allowing for a greater velocity/energy efficiency; however, the γ shape blade has a blade longevity factor in that once one side has been worn down, the blade can be flipped for a second use, effectively doubling the blade’s life. This is also an advantage over most straight blade designs. C-shaped blade Furthermore, the C shape does not have the ability to utilize a retaining pin for rapid blade changeout . The curvature angle of the blade (and therefore the blade's velocity and energy gain in comparison to a straight blade design) provides an equivalent lifetime based off of the material properties of the blade, namely its metal hardness. For modern metals, a cast blade can support a nearly negligible curvature without severely impacting its life, while a forged blade is capable of supporting a curvature angle that provides approximately a 7% increase in velocity (approximately 15% increase in energy) and a hard metal machined blade supports a curvature giving up to approximately 15% increase in velocity (approximately a 32% increase in energy) (utilizing a C shaped blade for maximum gain). The Rosler Way You can count on Rosler to help you find a better way when it comes to blade technology. Contact us today to discuss your unique challenges so we can identify the right blade for your needs.

Sauber Technologies continues pursuing technological innovation as it extends partnership with AM Solutions, a brand of the Rösler Group

Sauber Technologies has extended its technology partnership with AM Solutions – 3D post processing technology, a brand of the Rösler Group, taking a further step forward in the field of technological innovation. The partnership, which was sealed in 2021, has been prolonged for two additional years, as a logical consequence of a valuable and trustful business relationship that has been providing both parties with excellent results. Automated post processing of additive manufactured parts is essential for Sauber Technologies for the economical production of repeatable and high-quality printed parts, especially on an industrial scale. Over the last year, the company benefited from Rösler's decades of experience in surface finishing, by using post processing equipment provided by its brand, AM Solutions – 3D post processing technology. Several 3D printed parts have also been featured on the Alfa Romeo F1 Team ORLEN C42, bringing the strategic partnership from the factory to the track. Under AM Solutions – 3D post processing technology, the Rösler Group bundles all activities related to additive manufacturing with an outstanding range of products and services, including systems, consumables and process engineering for the series-ready and automated post processing of additively manufactured parts. Rösler's many years of cross industry experience in surface finishing in a real production environment as well as its own mechanical engineering form a strong backbone of AM Solutions offerings. As part of the relationship between Sauber Technologies and AM Solutions, the two partners are currently collaborating in the field of SLA (stereolithography) in post processing, to develop solutions to maximise the efficiency of the cleaning process and support removal, a further milestone in surface technology. In addition, Sauber Technologies is already using several mass finishing and shot blasting machines from AM Solutions. Christoph Hansen, COO Sauber Technologies: “Over the past year, the partnership with AM Solutions has been of fundamental importance, as several business practices of our Group have been employing them, from the wind tunnel models to the most experimental components, and, of course, our Formula One cars. AM Solutions have brought their excellent experience and solutions to Sauber Technologies, helping us creating 3D printed parts faster and in a more efficient way, two essential qualities for an ever-evolving business like ours. I am glad to be extending our partnership with the Rösler Group, and I am already looking forward to seeing what else we could achieve together in the future.” Volker Löhnert, Managing Director of Rösler Oberflächentechnik GmbH: "The extension of our partnership with Sauber Technologies is an important milestone for AM Solutions – 3D post processing technology. The team has a long tradition of using additively manufactured components in its Formula One cars and has been therefore interested in exploring the vast opportunities that 3D printing offers in terms of design, material selection, and lightweight construction. High-quality and repeatable post processing is of great importance for the optimization of the entire process chain, and that is where we bring our decades of expertise in surface finishing, together with our customized solutions developed specifically for the peculiarities of AM-manufactured parts. For these reasons, we have the perfect partner at our side in Sauber Technologies."

Husqvarna relies on intelligently linked Rösler equipment

In its chain link production Husqvarna is utilizing three Rösler FKS 35.1 A2-So centrifugal disk finishing machines along with a fully automatic Z1000 process water cleaning centrifuge. For over 10 years these machines have reliably handled highly demanding finishing processes in a 24/7 manufacturing environment. Because of this outstanding track record and the excellent cooperation Husqvarna called on Rösler to provide technical assistance with a capacity expansion project. The company installed an additional centrifugal disk finishing machine with convincing new technical features and a second automatic centrifuge equipped with the software package “digital process water management” developed by Rösler’s Smart Solutions team. The seamless integration and intelligent linking of the new with the already existing equipment made the production of chain links more flexible and more cost-efficient. Above all, it resulted in a higher overall stability of the finishing operation. Elimination of capacity bottlenecks in the surface finishing operation Prior to the expansion and modernization project the centrifugal disk finishing machines were assigned to specific mass finishing processes. The strict assignment was intended to prevent the mixing of different process liquids and, thus, facilitate the process water cleaning operation. However, this rigid organization of the centrifugal disk finishing machines did not allow their flexible use. For this reason, the available finishing capacity could not be utilized in a cost-efficient manner and caused frequent manufacturing bottlenecks. To provide more flexibility, the new centrifugal disk finishing machine is equipped with a dual dosing unit allowing the machine to be connected to two process water recycling systems. This allows running different finishing processes in the same machine. In combination with the new process water cleaning centrifuge and the resulting increased cleaning capacity the finishing machines can now be flexibly assigned to the actual processing jobs without affecting the overall surface finishing quality of the chain links. Innovative technical features increase the process stability and reduce the cycle times The new centrifugal disk finishing machine is equipped with a custom-engineered work piece loading system. In addition, the special design of the processing bowl offers a higher working volume. But that is not all: Special flow guide segments along with anti-slip bars, a special spinner design and an increased drive power ensure a much better mixing of the work piece batches weighing several hundred kilograms. All this brought about a higher finishing intensity with shorter cycle times, increased the overall productivity and produced more consistent finishing results. Husqvarna was also impressed by the fully automatic adjustment of the gap between spinner and processing bowl. Manual gap adjustment and time-consuming gap measurements could be completely eliminated. The “intelligent” control system is automatically setting the gap to a size that matches the work pieces to be processed. Moreover, the control system continuously monitors the gap size during the entire finishing process and automatically adjusts the gap as needed. Rösler is the only company that offers such an advanced gap control system! Of course, with this sophisticated technology even very thin work pieces cannot get stuck in the gap. This prevents premature wear and potential machine crashes. Besides a much higher process stability the automatic gap control also increases the equipment availability by eliminating the time required for manual gap adjustment. Complete process control and traceability The purchase order from Husqvarna also included the linking of the mass finishing machines with a subsequent manufacturing operation. It covered not only the transfer of processing programs and process data but also the integration of the finishing machines into the existing Manufacturing Executive System (MES) at Husqvarna. This ensures not only a complete process control but also the monitoring of the equipment status and the finishing parameters. Digital process water management – up to 50 % lower water usage and longer uptime of the process liquid The process water cleaning process at Husqvarna is quite demanding. Therefore, the company was pleased to integrate the digital process water management system from Rösler Smart Solutions into its modernized process water cleaning and recycling operation. This innovative, interactive monitoring system for semi- and fully automatic centrifuges allows the monitoring, collection and evaluation of all essential process parameters. Suitable problem-solving recommendations are automatically issued. This helps to significantly reduce the water consumption and increase the uptime of the process water resulting in considerable cost savings. Based on a preliminary analysis the time periods between process water changes could be extended by 50 %. The resulting increase of the process water uptime also amounts to about 50 %. On-time completion of this challenging project The capacity expansion and modernization project could be implemented within a tight and quite challenging time frame. Despite the current supply chain difficulties Rösler not only met the agreed upon delivery date but could commission the equipment at Husqvarna two weeks earlier. Rösler Smart Solutions – Improved surface finishes and lower reject The Rösler Smart Solutions system is also used at the Scherdel Waldershof GmbH & Co. KG. This company produces stamped and bent components as well as parts for the automotive industry from steel alloys, stainless steel and non-ferrous metals. The mass finishing operation requires not only excellent deburring and edge radiusing results, but the work pieces must also be perfectly clean for the subsequent optical quality control. The process water is cleaned with a semi-automatic centrifuge. In the past the somewhat limited quality control procedure for the process water checked only a few parameters resulting in unwanted media and metal residues on the finished work pieces. This required costly rework, before the components could be delivered to the customers. With the digital process water management from Rösler Smart Solutions the situation could be completely turned around. The well-organized data output and the easy-to-understand action points from the “digital guide” ensure that the process water remains stable at a high quality. In turn, this produces absolutely clean work pieces. With the digital process water management system the rework and scrap rate could be cut in half. Digital process water management improves process stability and increases cost-efficiency At the Wegmann Automotive GmbH, global leader in the field of balancing weights, the process water from the mass finishing operation is cleaned in a fully automatic centrifuge. In principle, the operator manages the water cleaning and recycling operation quite well. Nevertheless, the company decided to install the digital process water management system from Rösler Smart Solutions. Because of different technical requirements the company recently had experienced some difficulties. Weights made from steel receive a corrosion protection in the mass finishing process, while zinc components must have a specified surface tension for a subsequent coating operation. These different requirements led to either a too high or too low compound concentration in the process water, resulting in considerable rework and large quantities of scrap parts. The customer had not considered the consequences of a microbiological contamination. In this case the interactive digital process water monitoring system from Rösler Smart Solutions produced a much more stable process and drastically reduced the rework and scrap rate.

How to Use a Vibrascope to Measure Vibratory Bowl Amplitude and Frequency

When it comes to mass finishing , amplitude and frequency require balance and careful consideration. Amplitude is a measure of movement and intensity while frequency refers to the rate of repetition. The wrong amplitude, for example, can create lackluster finishing results and longer processing times if it is too low. If too high, it can cause unnecessary wear and tear on the machine. Creating Vibratory Energy Whether rotary or tub style , mass finishing vibrators always include two key components: a work bowl containing the finishing media and the work pieces. Firmly attached to this work bowl is a vibratory drive system generating the energy to put the media and work pieces in motion. The work bowl with an attached vibratory drive system sits on a number of coil springs – in some cases on air cushions – which in turn sit on a machine base. The springs, respectively, act as air cushions allowing the work bowl to “free float” up and down within a certain distance. Example of vibratory drive The force from the vibratory drive system moves the media and work piece mix within the work bowl. Depending on the type of finishing machine, this force is generated by vibratory motors or electric motors driving a shaft with one or multiple imbalance units attached to it. Imbalance units are made up of a rotating shaft with out-of-balance counterweights at each end of the shaft. Due to its imbalance, the rotating shaft causes an intense wobbling effect. Common drive systems in vibratory bowls and tubs include foot motors for small tub vibrators, flange motors for rotary vibrators, and multiple imbalance units with electric drives for large tub vibrators. The Effects of Vibration Since the work bowl with attached vibratory drive system is loosely sitting on the coil springs or air cushions, the energy induced by the vibratory drive system causes the work bowl to move up and down within a relatively narrow distance band at the speed of the rotary drive system. The maximum up and down displacement of the vibrating work bowl from its position of rest is an indicator of the vibratory intensity and is called amplitude. Measuring & Reading Amplitude Understanding your machine’s amplitude is part of the process to dialing in precise surface finishing results. The amplitude – actually the double amplitude from upper to lower peak – is mostly measured in mm. In finishing vibrators, the amplitude is usually between 3 and 6mm. Rosler uses a visual devise called a vibrascope, a sticker applied to the outside wall of the work bowl, to visually measure amplitude. This sticker contains a row of 7 circles with diameters from 1 to 7 mm. Example of Rosler's Vibrascope sticker The simplest way of reading the amplitude is by observing the vibroscope sticker as the machine is in operation. The vibration of the work bowl has the visual effect of showing two rows of circles, with some circles being completely apart and some overlapping. The two circles which are apart but nearly touch each other represent the observed amplitude value. Adjusting Amplitude The vibratory intensity or amplitude of a machine is determined by three factors. Adjusting one or more of these factors will adjust the resulting amplitude. Speed of the Vibratory Drive System – Higher rotary speeds produce higher amplitude. Mass of the Imbalance Weights – Heavier imbalance weights produce higher amplitude. Angle or “Lead Angle” Between the Two Imbalance Weights – Smaller angles produce higher amplitude. The highest intensity is produced at zero degrees, while the lowest – practically no vibration – is produced at 180 degrees. Rosler advises adjusting one factor at a time for the most accurate fine tuning as well as safety and longevity of the machine. The speed and amplitude in finishing vibrators cannot be increased beyond a certain value; otherwise the machine would destroy itself. The acceleration, consisting of rotary speed and amplitude must not exceed 6g. At high rotary speeds, the imbalance weights must be set for a low amplitude (mass of the imbalance weights and lead angle). At lower speeds, the imbalance weights can be set for a higher amplitude. The Rosler Advantage Machines built by Rosler run with more frequency and less amplitude, meaning our media contacts a workpiece more times and is gentler than competing machines. This unique advantage of Rosler equipment creates less wear on media and machines while producing greater longevity. The ability to reduce amplitude yet deliver the desired surface finishing produces less machine shaking and part damage while slowing the rate of machine wear. When using vibratory bowls and tubs, most of Rosler’s competitors hit harder. While impressive, the force of those hits may not produce the most efficient results. Finding the Right Settings In the above graph, the numbers highlighted in yellow are the optimal combination of amplitude and frequency. Amplitude settings depend on the machine set-up, workpiece condition, and desired outcome. Not sure what amplitude is best for your unique needs? Trust the experts at Rosler to conduct a trial and dial in the results before you purchase a machine. The Rosler Way Whatever your mass finishing needs are, you can count on Rosler to help you find a better way. Contact us today to discuss your unique challenges and request a free trial in one of our Customer Experience Centers .

New Deflashing Equipment Assists 30-year Customer Increase Production

For over 30 years, Berker GmbH & Co KG (Berker) has trusted Rosler shot blasting equipment in its manufacturing processes. A member of the Hager Group since 2010, Berker is one of the leading manufacturers of high-end electrical components, from timeless classical switches to intelligent electrical systems for buildings. The company also supplies switches for electrical appliances and automobiles. The Situation Berker primarily uses continuous feed systems such as loop and flat belt machines to deflash plastic components including switching elements, electrical outlet covers, frames, and more. Increased production volume at its Wenden-Ottfingen manufacturing location led Berker to decide to invest in an additional shot blast machine in 2018. The new investment was intended to replace an existing continuous feed loop belt system with the latest deflashing technology. Its specifications called for increased capacity and high equipment availability. The Solution After the capacity requirements had been established, Rosler developed a system concept that fully met the customer’s technical and economic demands known as the RSBS 1702 continuous feed loop belt blast machine. Equipped with two direct-drive blast turbines , the new Rosler machine produces excellent deflashing results combined with an extremely high degree of process stability. The machine includes a host of technical features including modern PLC controls, an optimized media cleaning and recycling system with a vibratory screen and air wash separator, a sensor-controlled media replenishment unit, automatic replenishment and mixing of anti-static compounds, noise protection, an automatic standby module, and a dust collector. The new machine design also allows the automatic deflashing of large work pieces which could not be handled with the old equipment and has been in operation since 2020. The Advantages Rosler is grateful to have the opportunity to assist a 30-year customer achieve new efficiencies even in the midst of a global pandemic and labor shortage. Automated aspects of Berker's new system went beyond improved efficiency and capabilities to provide an additional advantage in the reduced need for manual labor. Like many employers, Berker has faced increasing competition for manpower. The use of work piece handling systems, conveyor belts, and robots have helped bridge the gap in human resources and maintain production rates. Additionally, in the world of manufacturing, this mitigation of human intervention offers even greater and more measurable efficiencies and consistent quality. The Rosler Way “Finding a better way…” is more than a motto at Rosler; it’s our mission. With more than 80 years of experience and a portfolio containing more than 15,000 equipment and consumable products , solving challenges is what we do. Contact us to learn how we can help you achieve more efficient, automated surface finishing.

Hot Air and Media-Based Systems Offer Drying Options for Mass Finishing

With few exceptions, mass finishing processes require the addition of water and compounds to produce the desired results. That means finished work pieces discharged from the finishing machine are wet. Since possible corrosion or problems with subsequent manufacturing steps are possible, the finished work pieces must undergo a drying operation. While not as complex as the mass finishing process itself, drying nevertheless requires careful consideration to ensure that the work pieces are completely dry and free of any water or dirt spots. Rosler has extensive experience developing dryers for a wide range of work pieces and the expertise to assist with process parameters and settings. Work Piece-Based Machine Settings Machine settings for speed and temperature must be matched to the work pieces and their surface condition to ensure the lowest possible energy use to complete the task. For work pieces with complex shapes, including undercuts and/or internal passages, the dryer speed may have to be lower for a longer dwell time in the machine. In addition, the temperature setting may have to be higher. Work pieces with simple shapes can be dried at a higher speed and a somewhat lower temperature. Machine Types Dryers are categorized by their drying method, specifically based on whether they use a drying medium or hot air. Rosler offers a variety of machine options in both categories, each with its own unique capabilities. Rosler rotary dryer with supervelat Rotary Vibratory Dryers Known as the RT model range, rotary vibratory dryers utilize a drying media and are ideal for small- to mid-sized work pieces with relatively simple work piece shapes. Rotary vibratory dryers are the most common drying systems. Rosler belt dryer Belt Dryers The BT model range of belt dryers uses hot air to dry work pieces. These machines are ideal for mid-sized to large work pieces with complex shapes. Belt dryers are also widely used, especially when drying media might get lodged or trapped in the parts. Rosler drum dryer Drum Dryers Utilizing a drying medium, the TT drum dryer model range is particularly useful with mid-sized, cup-shaped work pieces as well as for parts that require gentle handling to prevent part-on-part damage. Rosler drying centrifuge Drying Centrifuges The hot air drying and work piece handling of the HTZ model drying centrifuge is capable of processing very small work pieces that are too small to be treated in other devices. The centrifugal force in combination with heated air ensures efficient drying of parts that are processed in batches. Special Rosler vibratory dryer Special Rotary Vibratory Dryers For drying operations that must be absolutely free of dust, such as polished coin blanks, special rotary vibratory dryers utilizing hot air are available. Determining the best options of various designs requires careful consideration of the overall process. Drying Media Maizorb drying media Made from crushed corn cobs, maizorb is the most common type of drying media. Its granule sizes range from approximately 0.002 to 0.2 in (0.5 to 5 mm). Regular replacement with new media is important to reduce the impact of residual contaminants, such as oil, media fines, and undersized media pieces, picked by the drying media. If not regularly refreshed, these contaminants can be transferred to work pieces. Stampings, for example, carry large amounts of oil into the finishing machine, requiring media replacement every few days. Conversely, media used in die casting processes can be used for a few weeks before being replaced. Work Piece Action Points As with any manufacturing process, regular observation is advised even with automated systems. For hot air and media-based operations, regularly check if the work pieces are dry when coming from the dryer. If not, change the machine settings (speed, temperature, airflow) to ensure that the work pieces are dry. In machines utilizing drying media, check dried work pieces for dirt spots on the surface. If spots appear, quickly replace the drying medium. The Rosler Way Decades of experience and ability to design, service, and maintain machines as well as the consumables and accessories to get the finish you require make Rosler a well-rounded surface finishing expert. Contact us to discuss your drying and general mass finishing needs.

Besser, schneller, wirtschaftlicher durch Simulationstechnik

Die Bedeutung der Oberflächenbearbeitung wächst in zahlreichen Industriebereichen. Die Forderung dabei lautet: Definierte Qualitätsanforderungen in kurzen Prozesszeiten bei geringstmöglichen Kosten ressourcenschonend erzielen. Diesem Anspruch wird Rösler unter anderem durch den Einsatz von Simulationssoftware bei der Konstruktion von Strahl- und Gleitschliffanlagen sowie der Prozessauslegung und -optimierung gerecht. Zeit- und kostenaufwendige Versuchsreihen im Customer Experience Center können durch den Einsatz der Software reduziert werden, Anlagen und Prozesse stehen schneller und mit größtmöglichem Kundennutzen zur Verfügung. Optimale Strahlergebnisse in kürzerer Zeit mit weniger Strahlmittel und effektiverem Lufthaushalt Der multiphysikalische Ansatz dieser modernen Simulationslösung ermöglicht anspruchsvolle Strahlprozesse anhand von 3D-Daten zu simulieren und optimal auszulegen. In die Simulation fließen alle prozessrelevanten physikalischen Randbedingungen ein. So lässt sich Strahlmittel virtuell auf beliebige Werkstücke applizieren, die sich wie bei der späteren, realen Bearbeitung bewegen. Die korrekte Darstellung der Strahlbilder und der Strahlmittel-Massenströme erlaubt dabei eine zuverlässige Auswertung und Anpassung des Trefferbilds und der Strahlleistung auf dem Bauteil. Der daraus resultierende, effektivere Strahlprozess sorgt dafür, dass geforderte Strahlergebnisse effizienter erzielt werden. Gleichzeitig verringert die gezieltere Applikation des Strahlmittels auf das Bauteil Verschleißerscheinungen innerhalb der Strahlkammer, wodurch Maschinenstillstandszeiten sowie Instandhaltungskosten deutlich reduziert werden. Ein weiterer Aspekt, der bei der Simulation betrachtet wird, ist die Staubbelastung in der Strahlanlage. Auf dieser Basis lassen sich konstruktive Maßnahmen für eine bessere Absaugung von Staubfrachten sicher und einfach definieren, sodass eine mögliche Staubexposition im Umfeld der Strahlanlage erheblich vermindert werden kann – und das auch bei bestehenden Anlagen, unabhängig vom Hersteller. Schnell zu idealen Gleitschliffprozessen für komplexe Werkstücke Die Entwicklung von Gleitschliffprozessen für geometrisch komplexe Bauteile, wie beispielsweise Knieimplantate, erforderten bisher aufwendige Versuchsreihen. Bei diesen Anwendungen bietet die Simulationstechnik ebenfalls entscheidende Qualitäts-, Zeit- und Kostenvorteile. Durch die Darstellung der Schleifkörperbewegung, wobei Schleifkörper in beliebigen Geometrien abgebildet werden können, und der effektiven Schleifwirkung auf dem Bauteil, lässt sich die ideale Kombination von Schleifkörper und Maschinenparametern ermitteln. In die Partikelsimulation kann darüber hinaus der Verschleiß der Anlage analysiert werden. Ein weiterer Vorteil der Simulation im Vergleich zu realen Versuchsreihen ist die Untersuchung von noch nicht gefertigten Bauteilen oder Systemen aller Art anhand von CAD Daten.

Mass Finishing Work Piece Handling Series, Part 2 – Preventing Drop Height Damage

Ensuring drop heights are not too high when raw work pieces are loaded into and exiting a mass finishing machine is an important consideration. Rosler has extensive experience developing mass finishing machines as well as material handling accessories to create a productive and efficient surface finishing system and prevent drop height damage. When evaluating drop heights and machine configuration needs, it is recommended that you consult an experienced equipment provider to help review key machine aspects and suggest solutions tailored to your unique needs. Issues to Avoid Falling from a loading container into a machine as well as moving from the machine into a post-process collection can cause damage to work pieces in the form of nicking and scratching caused by contact among work pieces as well as with the machine itself. More delicate and/or sharp work pieces, therefore, require extra consideration and evaluation of drop heights than sturdy and rounded components. For example, components with critical sealing areas, parts requiring a tight fit, and parts that need a high gloss polish must be handled with extra care. If big height distances must be overcome, chutes should be employed allowing the work pieces to gently slide down instead of just being dumped on top of each other, essentially “de-sharpening” the effect of contact. Similar caution must be employed at the various transfer points within a mass finishing system, for example, the transfer of the finished work pieces from the finishing unit to the separation station or from the finishing machine to a dryer, collection table, etc. The prevention of high drop heights should be one of the key questions for a supplier when considering the purchase of a new mass finishing system or modifying an existing system. Rosler offers a variety of transfer sections and attributes, including (from left) separation systems for coin blanks, separation screens to dryer to prevent part-on-part damage with gentle drop heights, and separation system with linear drive for extra gentle transport of parts. Media Considerations In addition to issues with work pieces, excessive drop heights can also cause issues with media . For example, unusual splintering or chipping of ceramic media may occur at transfer points if drop heights are too high or media is returned to the machine too quickly when external media separation is utilized, such as with inline trough machines . Media return conveyor of an inline trough machine. Media may also be prone to fracturing if heavy parts are dropped into the machine too aggressively. These media chips and fragments can lodge in the work pieces and cause problems in downstream processes or when the product is in use. Working with your equipment supplier is key to ensure that all transfer points in a finishing system allow a gentle media transfer as well as work piece transfer. The Rosler Way Our team of experts can help design, service, and calibrate a mass finishing system for your unique needs. Contact us to discuss your mass finishing and work piece handling needs. The complete Mass Finishing Work Piece Series includes: Part 1 – Selecting the Best Work Piece/Media Separation Method . Part 2 – Preventing Drop Height Damage . Part 3 – Maintaining Wear Linings .