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Optimized finishing process with a new, non-foaming plastic media

Better results, higher productivity and improved cost-efficiency In general, the optimization of mass finishing processes is mostly focused on the machinery. A finishing application at the job shop company Dörfler & Schmidt Präzisionsfinish has shown that by simply using a different media, a significant process optimization can be achieved. By switching to a new, non-foaming plastic media from Rösler the customer achieved a higher process stability, higher productivity and an improved efficiency. Founded in 1998, the Dörfler & Schmidt Präzisionsfinish GmbH offers a wide range of surfaces, such as deburring, edge radiusing surface smoothing, polishing, creating mat and structured finishes, descaling and cleaning. For these services the company is utilizing mass finishing, shot blasting and brush deburring equipment. The company is treating work pieces made from metal, plastic, ceramic, glass and wood. The work piece dimensions can range from a few mm up to 60 centimeters. The customers of this family-owned company, located in Kammerstein in the state of Bavaria, come from all kinds of industries like automotive, machinery building, electronics, medical engineering, jewelry and a variety of consumer goods manufacturers. A company utilizing different types of mass finishing technologies The highly heterogeneous clientele of Dörfler & Schmidt requires all kinds of surface finishing solutions. Felix Dörfler, executive assistant, comments: „We have to deal mostly with requests for deburring and edge radiusing. 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. On the other hand, jewelry and accessories must have an optically pleasing finish.” To be able to offer its customers the technically and economically best solutions, the company operates 33 different machines that can handle a broad range of different mass finishing technologies. Felix Dörfler continues: „To handle the various work piece materials we employ different process water cleaning and recycling systems. For this purpose we are utilizing five centrifuges, which like the overwhelming majority of our mass finishing equipment, were supplied by Rösler.” When it comes to consumables, Dörfler & Schmidt is also primarily using Rösler products. “The consistently high quality of the Rösler media and compounds and the excellent support in the field of process development and optimization by the Customer Experience Center are just a few reasons that right from the beginning we relied on solutions from Rösler”, concludes the executive assistant. New plastic media suppresses foam that interferes with the finishing process Mass finishing processes with plastic media pose frequently a problem with foam, even when so-called foam-reducing media are used. The extent of the foaming issue depends to a large extent on the hardness of the process water used in the finishing process. For resolving this problem, frequently special additives are utilized. This was also the case with an application at Dörfler & Schmidt. Felix Dörfler explains: „For the deburring and edge radiusing of 40 mm long stainless steel wire segments we need an excellent grinding performance with a high metal removal rate. However, the foaming during the finishing process created a buffer between the work pieces and the media, which reduced the grinding effect. Therefore, the desired finishing results could no longer be achieved within the prescribed cycle time”. But the unwanted prolongation of the cycle time was not the only problem. The separation of the finished work pieces from the media was also affected and did no longer function properly. The foaming issue was even carried over to the process water cleaning system, where foam was seeping out of the centrifuges. This soiled the system itself and the immediate environment. When the responsible Rösler sales agent was informed about this problem in July 2020, he proposed the use of a non-foaming plastic media that had recently been developed by the Rösler process engineers. Since the beginning of 2021, Rösler offers all standard plastic media types also in the non-foaming “N” version, which regarding the shape, size and grinding performance is identical with the old product. Since the use of the new media required no modification of the finishing process at Dörfler & Schmidt, the company replaced the old media with the new, non-foaming version. Higher process stability, improved efficiency and higher sustainability Dörfler & Schmidt is one of a selected group of companies who have tested the new media. The company has now been working with the non-foaming version for about nine months. The first test phase demonstrated impressively that the required processing results are safely achieved within the prescribed cycle time and that the separation phase also works well. The media switch to the non-foaming version has also greatly simplified the monitoring of the finishing process. Since the time for unwanted re-work could be completely eliminated, the overall cost-efficiency was significantly improved. Another benefit of the new media is that the usable life of the process water could be extended. This helped reduce the consumption of additives, a big plus for the environment and for achieving sustainability. Felix Dörfler summarizes: „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. 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”.

Wet Blasting Technology, Part 5 – PureFinish® Offers Food-Grade Excellence

Within the food, chemical, and pharmaceutical industries , hygiene is a top priority. For safety and quality assurance, the occurrence of contamination through bacteria, proteins, or other elements must be prevented. Process plants require a defined, homogeneous, and reproducible surface for all parts that come in contact with food, beverages, chemicals, and pharmaceutical products. Rosler delivers full compliance cleaning for stainless steel surfaces with PureFinish® , a unique wet blasting process. What is PureFinish®? Rosler developed this proprietary blasting process to deep-clean stainless steel components. Media specifically designed by Rosler for this environmentally friendly process remains suspended in water and is propelled onto the work piece surface with velocity. In the example shown, oxidation from welding on stainless steel components is completely removed after treatment with PureFinish®. Optimum Surface Finish The key advantage of PureFinish® is the optimum surface finish it achieves. The process creates a highly homogeneous surface profile with roughness readings of Ra = 0.25-0.60 µm. Not too rough and not too smooth, this profile is ideal for preventing bacteria from growing on and adhering to the surface. As shown below, bacteria growth only occurs if a surface is too rough or too smooth. Surface characteristics and goals This optimum surface profile allows easy removal of dirt and bacteria and, therefore, facilitates cleaning and sterilizing the surface. Additional advantages include: PureFinish® meets all hygienic requirements of the EHEDG (European Hygienic Engineering & Design Group) . Much lower ratings on the Soil Retention Index (SRI) compared to stainless steel surfaces cleaned with other cleaning methods. Considerably fewer contaminants left on the surface. The purely mechanical process does not require any hazardous pickling chemicals. PureFinish® creates a peening effect on the surface that makes the component more durable and prevents premature corrosion due to stress cracking. A welded work piece before and after PureFinish® treatment The Rosler Way With more than 80 years of experience in surface finishing, the Rosler team has expertise in the wet blasting field. This experience allowed us to create PureFinish® and its unique capabilities. To demonstrate our capabilities, we offer FREE sample processing in our global test centers . Contact us to discuss your wet blasting goals and challenges. The complete Wet Blasting Technology Series includes: Part 1 – “Wet Blasting Gently Delivers Dramatic Finishing Results.” Part 2 – “Comparing Attributes, Advantages to Dry Blasting.” Part 3 – “Technical Features, Slurry Control Achieve Precise Finishing.” Part 4 – “Typical Wet Blasting Applications.” Part 5 – “PureFinish® Offers Food-Grade Excellence.” Sign up for enews alerts to be notified of all Rosler blog posts!

Rösler Anti-Dust: An additive for the dust absorption in drying processes with drying media

Over 90 percent of all mass finishing applications are wet processes, where the finished work pieces must subsequently be dried. For this purpose, driers, filled with organic granules such as maize-cellulose product, are frequently utilized. Unfortunately, these organic materials are producing dust. The Rösler Anti-Dust additive reduces the dust formation significantly. Anti-Dust is an easily dispensable liquid additive that can be used for drying of all kinds of metallic and plastic work pieces in conjunction with drying media. Already small amounts of Anti-Dust additive are effective over a period of several days and can be quickly replenished as needed. Without affecting the drying performance, it ensures less residual dust on the work pieces, in the environment and in the dryer. Environmental compatibility also played an important role in the development of this product. Anti-Dust consists of plant based materials and, in addition, is as safe as food. The benefits of Anti-Dust at a glance: Less residual dust in the dryer and the environment Spot-free drying of the work pieces No negative effect on the drying performance Made from ecologically sustainable materials and as safe as food Liquid additive that allows easy dosing

Preservation Lines Deliver Multi-Step Surface Finishing in a Single Machine

Complete systems for blast cleaning and placing a protective coating, preservation lines are extremely useful on plates and profiles that require multiple treatments. For example, structural steel components are commonly processed by preservation lines because they are prone to rust quickly and fail with potentially catastrophic consequences if not covered with a suitable, protective coating. Rosler has extensive experience preparing structural steel components for use in construction , shipbuilding , and the production of all kinds of heavy-duty vehicles, trucks, railway vehicles, agricultural implements, or construction equipment. We understand the importance of applying proper surface finishing processes to these components for safety and longevity. Offering shot blasting , painting, and more in a single source, preservation lines are a great option for a variety of industries , especially those utilizing structural steel components including steel plates, beams, round bar stock, and tubes. Components & Functions Preservation lines incorporate material handling, blast cleaning, and protective coating and/or painting in a single process. While customized options and accessories can be added in, preservation lines typically include six key components. Rosler's preservation lines are customizable to your needs. This diagram shows common components included. Material Handling (1) These integrated transport systems utilize roller conveyors, cross transport units, and other methods to move sometimes large and heavy work pieces before and after processing within the preservation line. Blow-Off Units (2) Designed to remove water, dust, leaves, and other loose contaminants before blasting, these stations help ensure components are clean enough for the subsequent finishing process. They may also be combined with brush-off units. Rosler blow-off unit Pre-Heaters (3) Used in front of the shot blast machine to melt snow and ice, pre-heaters ensure that the work pieces do not carry any moisture into the shot blast machine. The pre-heater also serves a dual function, bringing work pieces to the optimum temperature of about 100° F (40° C) for the subsequent cleaning coating process. Shot Blast Machines (4) Using propelled media , this section of the machine removes rust and scale from the work piece and creates the correct pre-paint surface profile/roughness. Work pieces move through the shot blasting area on roller conveyors . Paint / Coating System (5) Automatic, high-speed, gantry paint systems apply paint and protective coatings in this step of the process. The paint cabin also contains any overspray and paint fumes through mist filtering, roller brush systems, and the air filtration systems. Paint Dryers (6) Post treatment of components within the drying station ensure that paint and coatings applied in the paint cabin are appropriately dried and cured for improved adhesion and life expectancy. These dryers frequently utilize excess heat from the pre-heater to minimize power use by up to 10 kW. Rosler paint dryer The Rosler Way Rosler has the experience and expertise to solve your surface finishing challenges by developing a preservation line to meet your needs. We partner with you to find a better way, the best machine, and the best finishing results. Contact Rosler today to discuss your unique challenges.

Optimized finishing process at Gardena increases productivity and lowers costs

Improved productivity, increased production capacity, better quality and lower costs. These were the demands of a leading garden tool manufacturer, when he invested in a new mass finishing system for deburring and polishing of garden shear knives. Rösler met this challenge with a tailormade Keramo-Finish process that is run in a double batch centrifugal disk finishing machine FKS 35.1 A2-So with fully automatic work piece handling. In a two-stage process the stamped and laser-cut knives are deburred and polished in the FKS finishing machine. Subsequently they are dried in an energy-efficient rotary dryer and prepared for the next manufacturing step. For more than 60 years, Gardena, a brand of the Husqvarna Group, has been offering everything ardent gardeners need. The broad product range includes innovative systems for irrigation, lawn, tree and shrub care, as well as soil cultivation. Gardena products are used in more than 80 countries all around the world. A transformation to ultra-modern equipment and process technologies To ensure easy and simple handling, produce excellent cutting performance and guarantee a long service life, the shear components are produced with state-of-the-art manufacturing technologies. Important steps are the stamping or laser cutting of the upper and lower knifes followed by a deburring and polishing process in mass finishing equipment. Previously the lower knifes required two separate finishing operations, one in a rotary vibrator and one in a centrifugal disk finishing machine. To combine these two operations into one and adapt them to the latest manufacturing requirements, the existing mass finishing equipment, used over many years, was replaced. Gardena chose a finishing solution from the Rösler Oberflächentechnik GmbH, who had already supplied the machinery used to date. By investing in new equipment the customer was looking for a comprehensive optimization of the finishing process that improved not only the productivity and offered a higher capacity but also resulted in lower costs. A finishing system that produces shorter cycle times and improved operational efficiency Based on the surface finishes of the steel knifes that are required for the next manufacturing steps, the Rösler process engineers ran a series of processing trials in their test lab with various processing media and different process parameters. The best results were achieved with a Keramo-Finish process in a centrifugal disk finishing machine. This includes the use of a ceramic media with minimal abrasive characteristics in combination with a grinding and polishing paste and a cleaning compound with a distinct brightening effect. The new process allows the deburring and polishing of all knifes in one single machine. The rotary vibrator was no longer required, and the work piece handling was simplified. Moreover, depending on the work piece type, the new Keramo-Finish process reduces the processing times by 25 % to over 100 % and also allows bigger work piece batches. This helped to reduce the operational costs by around 10 % with, at the same time, greatly improved finishing results. Fully automatic processing in a double batch system The new double batch centrifugal disk finishing machine was perfectly integrated into the manufacturing flow at Gardena. Work piece specific processing programs stored in the PLC controller allow the targeted finishing of the various knife types. After stamping, respectively, laser cutting the work pieces are collected in perforated metal bins. The operator utilizes a swing crane to dump the raw knife components into a loading device that transfers them into a vibratory feed hopper. After the respective finishing program has been manually selected, the hopper automatically feeds a work piece batch into the work bowl for processing. After the preset finishing time the work bowl gently dumps the mix of finished work pieces and media onto a vibratory hopper from where the mix is transferred to a vibratory separation unit. There, with a precisely sized hole screen, the media and finished work pieces are separated from each other. At the same time, a special undersize media screen is discharging media that is no longer suitable for the finishing process. This guarantees a continuous high process stability. While the media is returned into the work bowl, the finished knife blanks are transferred to the drying station filled with a maize-cellulose product. The rotary dryer RT 550 Euro-DH is equipped with an innovative new heating system that guarantees not only fast, reliable and spot-free drying of the work pieces but also produces energy savings of up to 40 % compared to conventional rotary dryers. After completion of the drying cycle the knifes are transferred to another vibratory hopper that loads them into waiting small transport carriers made from plastic. A fully automatic Z 1000 centrifuge is cleaning the process water and recycling it back to the mass finishing system for re-use in the finishing process. This helps save valuable resources. The drastically reduced water consumption, along with the innovative finishing solution and well-planned process controls ensure a sustainable and efficient operation of the new mass finishing system.

Centrifuge Technology, Part 3 – Mechanics and Limitations of Water Recycling

Combining the direction of rotation and centrifugal force, Rosler’s centrifuge technology takes advantage of the weight difference between the liquid phase and the solids in the process water to separate “dirty” solid particles from clean, reusable process water. The effectiveness of this technology lies in the centrifugal force that is created. For example, a modern fighter jet develops a G-force of about 10-15 while a high-speed centrifuge drum generates a force of more than 2,000 G. The physics of centrifuge technology combined with mass finishing equipment creates efficient and ecologically sound manufacturing processes, albeit with some key limitations. Collection by Force The solids, primarily consisting of media and, to a lesser degree, of metal fines from the work pieces, found within “dirty” process water are heavier than the water itself. As the drum spins, heavier solids are deposited on the drum wall in the form of sludge, whereas the lighter-weight liquid remains on the inside of the drum. With the addition of special cleaning additives known as flocculants, even oil carried into the mass finishing process can be removed from the process water. As shown in the diagram below, dirty process water is pumped down into the centrifuge drum (1) which is then accelerated by the applied centrifugal force. While the cleaned water is picked up by a so-called collection tube (2) for reuse, the sludge (3) is collected and periodically removed from the drum by mechanical or manual means. Limits of Cleaning The presence of solids in the process water is a must. Centrifuge technology works best when the process water contains a certain amount of solids and there is a notable weight differential between the liquid phase and the solids. Through the addition of special water cleaners, centrifuges can also remove oil from mass finishing process water, provided, of course, that the oil content is not too high. There are a few exceptions in which certain applications produce no or only very few solids in the process water, making centrifugal cleaning difficult or impossible. This is the case with: Ball burnishing and pressure deburring when steel media is used instead of ceramic . Part-on-part finishing when no media is used at all. High-end polishing operations where residual solid particles in the recycled process water might negatively affect the polishing quality. While process water from these applications is not suitable for centrifugal cleaning and recycling, it must be cleaned with other cleaning methods prior to discharge. Disposal of the Depleted Process Water If properly maintained, process water can last for a long time, usually between 3 to 12 months. Once it becomes too contaminated for cleaning, it must be replaced with a new batch of fresh water and compound. Reasons for depletion include: An abundance of solid fines which are too small to be picked up by the centrifuge. Too much oil carried into the finishing process. A bacteria buildup due to poor maintenance. The build-up of salts in the water that affect the finishing process. In such cases, the depleted process water must be cleaned in a “floc & drop”, membrane, or evaporation system prior to disposal. Depending on the type and level of contamination in the “dirty” water, straight sewer discharge could be illegal, costly, and/or unsafe. The Rosler Way The experts on the Rosler team can help identify the best centrifuge technology for your unique process challenges and develop solutions accordingly. Contact Rosler today to learn how we can improve and enhance your mass finishing process. Previous posts in the Centrifuge Technology series include: Part 1 – “Water Cleaning Systems Replace Outdated Methods.” Part 2 – “Operational and Economic Benefits of Recycling Process Water.” Part 3 – “Mechanics and Limitations of Water Recycling.” Part 4 – “Pre-Conditions and Consumables Enhance Process Efficiency.” Upcoming posts in the Centrifuge Technology series will include: Part 5 – “Potential Issues and Remedies for Water Recycling.” Sign up for enews alerts to be notified of new posts!

New continuous flow wire mesh belt blast machine from Rösler runs more efficiently and saves valuable resources

Over the course of a project to improve overall productivity and to make the coating of WPC (wood plastic composite) profiles more eco-friendly, the Jürgen Schröder GmbH has invested in new machinery. Specifically, the company purchased a new wire mesh belt machine RDGE 600-L from Rösler. The Jürgen Schröder GmbH, founded in 1980, has established itself in the market as a painting job shop for wooden windows, sun rooms, planed components, all kinds of moldings, doors, etc. For painting wooden components the company, with many years of experience, is also utilizing ultra-modern coating technologies. Decisive factors for choosing the continuous flow wire mesh belt blast machine RDGE 600-L were the excellent quality, the machine design tailored to the company’s requirements and the professional support by the Rösler sales team. Strict requirements regarding performance and sustainability At the moment the WPC profiles, such as base boards or floor boards for decks, are extruded at the suppliers with the color requested by the customers already mixed into the molding compound. This causes frequent production stoppages and material losses at the extrusion lines, whenever a color change takes place. Therefore, it is not surprising that all involved parties wanted to eliminate these color changes by applying the desired color after the extrusion operation. A tailormade equipment concept thanks to the Rösler experts Pre-condition for the optimal adhesion of the applied paint is the best possible surface preparation of the material substrate. The experts from Rösler and the Jürgen Schröder GmbH worked closely together to develop a process that not only met but exceeded the customer’s expectations. Tests to find out how the coatings perform under the most severe weather conditions and mechanical load tests proved very quickly the positive results so that the project could be implemented on an industrial scale. Subsequently, Rösler developed a shot blast solution that is perfectly adapted to the specific work piece requirements and the capacity demands. The new system is also in full compliance with the existing and new logistical manufacturing conditions. By purchasing the continuous flow wire mesh belt blast machine RDGE 600-L the customer could also take advantage of this machine’s small footprint, its high cost efficiency, its ease of maintenance and excellent uptime. The RDGE is equipped with two extremely wear resistant and easy-to-maintain high performance turbines . These are throwing the blast media on the WPC work pieces passing through the machine at a closely controlled speed and impact energy. The effect is a perfectly structured, isotropic work piece surface. An integrated blow-off system is removing all residual blast media and other particles from the shot blasted work pieces. The particular work piece material required the installation of a dry dust collector with built-in explosion protection. Of course, the dust collector is in full compliance with all industrial safety regulations. The shot blast machine, tailored to the specific customer’s needs, met not only his requirements regarding performance, cost and energy efficiency and equipment uptime, but it also represents a significant contribution towards environmental compatibility. Björn Schröder, general manager of the company, summarizes his expectations for the new shot blast machine: „Sustainability and a policy that protects valuable resources have always had a special place in our corporate philosophy”. Against this backdrop it was only natural that the project was partially funded with a grant from the European fund for regional development. „We were impressed by the excellent equipment engineering and the professional advice of the Rösler people at our location and at Rösler’s test center. The integration of the shot blast machine into our existing manufacturing line could also be implemented without any flaws. We will contact Rösler for any future shot blast projects”, summarizes Björn Schröder, general manager of the Jürgen Schröder GmbH.

Polishing Processes Benefit from Pre-tumbled Media

Media selection is key in any surface finishing process since these consumables are essential “precision tools” required to achieve the specified finishing results. Whether you are developing a new mass finishing process or changing process parameters including different work pieces, process times, and requirements, partnering with an experienced expert will help you in evaluating all process parameters. With decades of experience developing mass finishing machines and manufacturing media and compounds , Rosler is an excellent source for guidance. In some cases, pre-tumbled media may be suggested. What is Pre-tumbled Media? After production, some types of pre-polishing and polishing media are pre-tumbled by the manufacturer. This process breaks sharp points and corners off individual media pieces to create smoother edges. Without this step, media still has sharp edges and a relatively rough surface. For heavy‐duty deburring and surface grinding this abrasiveness produces a welcome benefit. Yet for pre‐polishing and polishing purposes it is a distinct disadvantage since the initial surface conditions of the media can cause micro scratches and prevent the desired smooth/polished finish. Polished knives processed with pre-tumbled media When is Pre-tumbled Media Useful? The need for pre-tumbled media applies primarily to finishing tasks requiring a very smooth surface finish with the ultimate goal of a high-gloss polish. These polishes can only be achieved with pre-tumbled media. In addition to the desired process, the state of the process may also factor into the need for pre-tumbled media. For new processes requiring a complete load of new media, the use of pre-tumbled media is an absolute must while media for established processes may not need pre-tumbling if only small quantities of new media are added to offset media wear and undersized media discharge. When in Doubt, Test Your Media. Whether your process uses ceramic, plastic, or drying and polishing media, a crucial step in selecting media should always be consulting experts, i.e. your supplier. Since a media change might require extended test trials, an experienced partner should test prospective media with your specific work piece in their test lab. Rosler test center The Rosler Way With more than 80 years of experience in surface finishing, the Rosler team is well equipped to provide media selection guidance and FREE testing in our global test centers . For new processes and adjustments, contact us for all your surface finishing and media needs!

Double-batch mass finishing system for wet and dry finishing process

Highly flexible and efficient solution for processing of zinc die-castings Gjuteriteknik, a Swedish foundry specialized in zinc die-casting, was looking for a mass finishing system that allows the fully automatic and cost-efficient running of different finishing processes. With the mass finishing system R 420 2-CH Rösler was able to provide the ideal solution. This system allows the simultaneous dry or wet processing of two work piece batches, including the drying of the finished work pieces, with a high degree of process stability. In the mid 1990’s the foundry Gjuteriteknik AB, founded in 1978, made the strategic decision to exclusively specialize in the production of zinc die-castings. This family-owned company, located in Värnamo, Sweden, and run by the second generation owners Jonas und Peter Abrahamsson, has successfully established itself in this field and produces about one million castings per day. The company’s services include the design phase for a product, the production, surface refinement and logistics. With this comprehensive portfolio the zinc die-casting specialist Gjuteriteknik is partner of a wide range of companies active in the fields of telecommunication, electronics, automotive, furniture and construction in Europe, Asia and South-America. A recipe for success - flexibility, quality and automation Jonas Abrahamsson comments: „Zinc die-casting is a relatively small segment in the foundry industry. To be competitive on an international level, as a Swedish company we must not only be highly flexible in the fulfillment of the customer requirements but must also be very cost-competitive. We have achieved this by the implementation of highly automated processes throughout our entire manufacturing operation”. Mr. Abrahamsson continues: „Our goal is to produce casting qualities that require no additional processing. However, if the work pieces had to be deburred, we did this predominantly in fully automatic shot blasting cells. One reason for this approach was that our old mass finishing system offered only very limited processing possibilities and required a lot of manual operations”. Therefore, when the company decided to purchase a new mass finishing system, its main requirements were flexible processing possibilities, an automated process from the loading of the work pieces to their discharge after the drying operation and a high capacity. Because of its excellent experience with the existing Rösler mass finishing and shot blast equipment, Gjuteriteknik decided to purchase a system that consists of a double-batch rotary vibrator, model R 420 2-CH , a hot air belt dryer and a centrifuge for cleaning and recycling of the process water. Another reason for purchasing the Rösler system was that it fully met the cycle time requirements of the customer. Efficient, parallel wet or dry processing At the center of the double batch system, allowing the parallel processing of two work piece batches, is a rotary vibrator with a gross volume of 420 liters that is suitable for wet as well as dry finishing operations. „We already had one project for dry finishing of the work pieces. And we knew that the demand for dry finishing would grow significantly. Therefore, it was very important for us to process the work pieces fully automatically, which so far had not been possible. For this reason, process flexibility had top-priority”, explains the managing director. For the mass finishing operation customer-supplied bins with raw work pieces are placed into the lift and tip loading device that transfers the work pieces into a vibratory hopper. After the operator has entered the work piece identification into the PLC, the work piece specific processing program starts automatically. While the vibratory hopper transports the raw zinc die-castings into the rotary vibrator, the loading device moves back into its home position. This allows placing another batch of work pieces into the loader and selecting the respective program. After the pre-programmed processing time an unload gate in the bottom of the rotary vibrator is opened, and the mix of media and finished work pieces is discharged onto a vibratory buffer with an infinitely adjustable vibration intensity. As soon as the processing bowl is empty, the unload gate is closed, and the processing bowl is filled with another batch of media and raw work pieces. At the same time the vibratory buffer gently transfers the mix of finished work pieces and media into the vibratory screen separation unit, where media and work pieces are separated. An undersize media screen ensures that during the separation operation media that has become too small, is discharged from the system. This ensures a high process stability. Within certain time intervals new media is manually added to the system. The area around the vibratory separation unit was designed as a separate safety zone, which can be safely entered, while the rotary vibrator is running. This allows placing empty part bins for work pieces that were finished in a dry process and discharged through a movable vibratory cross conveyor. Work pieces that underwent a wet finishing process are transferred to the two meter long hot air belt dryer R 2000 BT. Cleaning and recycling of the process water by centrifuge During wet finishing processes a high water-compound flow through the rotary vibrator ensures a complete and safe flushing out of contaminants such as metal and media fines, etc. The water/compound mix flows into the rotary vibrator from the top, is discharged through bottom drains and then pumped to the semi-automatic centrifuge Z 800. To promote the separation of the solids from the process water in the centrifuge, flocculants are automatically dosed into the process water. The cleaned water is pumped to a clear water tank. As needed, compound is injected into the process water fully automatically. This guarantees a constant compound concentration and, therefore, absolutely repeatable, high-quality finishing results. Jonas Abrahamsson concludes: „The new mass finishing system permits us to adapt our finishing processes to the work pieces and, thus, enables us to perfectly fulfill the requirements of our customers. We are very happy with the new equipment and feel that we are well prepared for any future finishing challenges”.

wet blasting technology, part 4 - typical wet blasting applications

Wet blasting can do nearly any job that is done with dry shot blasting . The defining differences are that wet blasting does so more gently and without producing dust. In addition, wet blasting can handle a small amount of oil and grease unlike dry blasting. At Rosler , we have more than 80 years’ experience in surface finishing . While wet blasting has gained popularity recently, we’ve used this technique to provide precise, repeatable results to a number of industries over the years. Typical Applications With proper testing and process parameters, wet blasting can achieve numerous surface finishing goals. Cleaning A fastener with heat discoloration before versus after wet blasting. Depending on the work piece’s starting condition and successive finishing steps, rust, scale, oxidation, road grime, grease, and oil may need to be removed. Wet blasting can accomplish a variety of cleaning applications including: Dies and molds such as die castings and tire and glass molds. Automotive rebuilds such as engines, transmissions, brakes, etc. Investment castings such as boat propellers, pump impellers, housings, valve bodies, etc. Aircraft engine rebuilds. Various components before inspection or secondary processing. Burr Removal Hydraulic components before and after wet blasting. Work pieces with flashings and burrs must undergo deburring and deflashing. For example, firearm components require burr removal after drilling, milling, and turning. Drill bits and milling tools also require burr removal. Descaling Despite the newest heat treatment processes, discoloration, oxidation, scale, and hard residues are found on cast and forged products as a result of manufacturing and environmental influences. Modern production methods, control and testing processes, and an uninterrupted continual processing of the cast and forged parts requires clean, light work piece surfaces. Surface Texturing Creating a somewhat rougher surface finish is a key step in preparation for painting, coating, and bonding with glue. Ensuring that subsequently applied coatings have a rough enough surface to adhere to improves the quality and life span of a work piece. Examples of wet blasting applications for surface texturing include: Preparation of automotive parts for rubber coating such as brake and engine seals. Surface preparation to place a corrosion protection coating for screws. Surface preparation to place a primer on airplane components such as rotor blades, stringers, and wing spars. Orthopedic implants in which osseointegration and bone growth around the implant are encouraged. Light profiling of tibia plates, knee femorals, hip stems, and spinal implants helps promote this bone growth. Stripping of Paint and Coatings Wet blasting is ideal for stripping of paint and coatings from delicate work pieces. Processing of mineral-based construction materials such as concrete or sandstone, glass, textiles, and wood is possible with Rosler machines as well as the finishing of plastics and metals. Cosmetic Finishing Wet blasting removes machining lines from aluminum gun bodies as shown in these before and after examples. Wet blasting serves as an excellent method of applying a uniform, matte finish on work pieces. This finish can take various forms, including: Creating a pre-polish finish smoother than what can be achieved with dry blasting. Applying a non-glare, matte finish such as the finish required for surgical instruments. Masking machining lines on a variety of parts like tibia implants or aluminum gun bodies. Shot Peening Landing gear includes many wet blasted components. Shot peening is a process specially developed to improve the properties of components which are exposed to changing strains. For safety reasons, shot peening is also now absolutely necessary in the aviation and space industries . Shot peening is also essential in all industries requiring long lives for components including the automotive sector. Wet blasting applications for shot peening are mainly used in conjunction with Almen strip N for glass beads, ceramic beads , and stainless steel shot . Additive Manufacturing Post Processing Additively manufactured components before and after wet blasting. Wet blasting is an essential technology for various post processing tasks, specifically additive manufacturing. Wet blasting cleans the 3D printed components by removing residual powder and significantly reduces their initial high surface roughness. It is capable of de-powdering and providing general surface cleaning and initial surface smoothing from Ra = 1,000 micro inches down to Ra = 40-60 micro inches (25 µm to 1–1.5 µm). On metal AM parts the loosely sintered grains on corners are effectively removed. The wet process eliminates the worry about residual powder containment or sparking during the blasting process. De-contamination of nuclear power plant components Manual wet blast cabinets allows for same removal of contaminants. Removal of small, radioactive fragments from the component surface in nuclear power plants can also be achieved through wet blasting. The process decontaminates the components to a point where they can be declassified as radioactive. Special consideration regarding the water treatment are required to meet the requirements for this application. The Rosler Way With a trusted partner such as Rosler, you don’t need to worry about the ins and outs of an application. Contact us to discuss your wet blasting needs and challenges and we will deliver a solution. We’ll even demonstrate results with FREE sample processing in one of our global test centers . That’s the Rosler Way. The complete Wet Blasting Technology Series includes: Part 1 – “Wet Blasting Gently Delivers Dramatic Finishing Results.” Part 2 – “Comparing Attributes, Advantages to Dry Blasting.” Part 3 – “Technical Features, Slurry Control Achieve Precise Finishing.” Part 4 – “Typical Wet Blasting Applications.” Part 5 – “PureFinish® Offers Food-Grade Excellence.” Sign up for enews alerts to be notified of all Rosler blog posts!