Aerospace, Part 3 – Drag Finishing for Airbus Helicopters

The aerospace industry demands high repeatability and adherence to strict production tolerances. As we discovered in Aerospace, Part 2, Rosler Metal Finishing’s drag finishing systems produce exact results every time.

 

 

Airbus

Helicopters

 

 

After using Rosler drag finishing systems for a number of years, Airbus Helicopters knew just who to turn to for help with a new helicopter model.

 

 

We

took on the challenging task of finishing larger gear components for the new

design as well as incorporating expanded capacity for their existing helicopter

models, developing an innovative drag finishing system with automatic work

piece clamping and a clever work piece handling system.   

 

 

 

Based

on numerous processing trials in our test center, Rosler developed an entirely

new drag finishing concept that meets all customer requirements. Flexible yet

robust, the new drag finisher is capable of finishing approximately 35

different work pieces made from special, high-performance steel alloys with

diameters from 40-800 mm and individual weights of up to 75 kg.

 

 

 

 

Technical

Specifications

 

 

 

With

work bowl dimensions of 1,700 (H) x 2,600 (Ø) mm, this new machine is one of

the largest ever built.

 

 

 

To

allow the operator easy, ergonomic access to the work stations, the machine was

placed in a foundation pit. Three 3.6 kW vibratory motors mounted to the

sidewall of the work bowl ensure that the processing media in the work bowl

weighing about 6.7 metric tons is thoroughly mixed in between process cycles.

 

 

Rosler R6/2300

 

 

A

crane placed behind the machine allows easy and quick filling of media into the

work bowl. Worn media that has become too small is discharged through screens

in the work bowl bottom. A level indicator shows the operator when to add new

media, which is done manually. A Z1000 centrifuge with fully automatic sludge

discharge cleans the process water, with a timer controlling the automatic

compound replenishment.

 

 

 

The

rotating carousel (spinner) is equipped with six workstations with independent

rotary drive units. Additionally, the workstations can be shifted to form a

smaller or larger circle with adjustable angles. The system allows the

simultaneous processing of two large and four small gear components.

 

 

 

Since

some of the work pieces are quite heavy, they are loaded/unloaded with a part

manipulator. The operator guides the handling system holding one single work piece

in a precisely defined position to the workstation. After the work piece has

been mounted to the station, it is automatically clamped. Smaller gears are

mounted manually. 

 

 

 

Based

on the cycle times in the existing drag finishing system, the process parameters

like circular orbit, rotary speed, and covered distance were translated to the

larger, new machine in a manner so that no changes had to be made to the

existing finishing process.

 

 

For unloading the finished work pieces, the carousel moves into a position that allows the operator to spray-rinse them with water and then remove them from the workstation.

 

 

Monitoring

for Process Safety

 

 

 

In

order to meet the high safety standards required in the aerospace industry, all

equipment functions are continuously monitored and controlled. This includes

the movement of the work piece handling system as well as the correct

positioning of the work pieces in the workstation clamping system. Any

deviations will cause the automatic stop of the machine.

 

 

Rosler drag finishing equipment

 

 

To make

certain that the process water is safely evacuated from the work bowl, the

draining screens in the work bowl bottom are not only flushed with water but

also regularly cleaned with compressed air. Maintenance is made easy with a

central lubrication system that automatically supplies the guides and

workstations with grease according to preset time intervals.

 

 

 

The

Rosler Way

 

 

 

True

to our motto of “finding a better way,” Rosler considers all inputs and outputs

of your process. We offer experienced finishing engineering and an entire range

of surface finishing equipment and consumables (media and compound) to ensure

that the entire process is optimized.

 

 

Whatever your aerospace finishing needs are, you can count on Rosler Metal Finishing to find a better way. Contact us today to start the conversation.

 

 

The complete Aerospace Series includes:

 

• Part 1 – Cost Effective, Mechanical Finishing for Large, Structural Aircraft Components.
• Part 2 – Innovative Finishing for Aerospace Components.
• Part 3 – Drag Finishing for Airbus Helicopters.

 

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