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Part-on-Part Mass Finishing, Part 1 – Utilizing Work Pieces as the Media

Mass finishing processes require pressure and constant rubbing to achieve the desired finishing results. In most cases, these applications require media specifically selected for its material, size, and shape to act upon work pieces and achieve the required effects. Some mass finishing applications also seek to eliminate or reduce part-on-part impingement or contact to protect delicate and high-value work pieces. Conversely, part-on-part mass finishing intentionally exposes work pieces to impingement and encourages contact between work pieces and the resulting pressure to create finishing effects without the need for ceramic, plastic, and other types of media . The only additives required for such part-on-part finishing are water and the respective compounds . Rosler Metal Finishing designs part-on-part mass finishing machines, known as WTA machines , which help reduce cost per piece through the elimination of media consumption and faster processing times. Ideal Work Pieces Part-on-part finishing is ideal for small, bulk parts that are made of brass, steel, aluminum, and even small ceramic components. Contact pins Pre-conditions for work pieces exposed to part-on-part finishing include: Small sizes, approximately 0.1 to 2” in length or width. Simple, compact shapes. Sturdy nature without a need for delicate handling. Zipper components Part-on-part finishing is commonly used for: Small chain components including rollers and bushings. Small eyelets and hooks. Small stampings such as electrical contacts. Metal buttons. Rivets. Small metal tubing. Zipper parts including sliders and pull tabs. Rollers for small roller and needle bearings. Electrical contact pins. Small spindles and shafts. Ammunition cartridge components including blanks and cups for casings, deep drawn casings, bullets, and primers. Rivets Finishing Processes With the right compound(s) and suitable dosing system, part-on-part finishing machines can handle nearly any type of surface finishing task. Descriptions of finishing tasks and the suggested compound include: Cleaning, degreasing, and de-oiling – In order to remove dirt, grease, or oil from the surface of the work piece, these tasks use pH neutral/slightly alkaline compounds. Pickling – This task utilizes a highly acidic compound to remove oxidation and light scale left over from annealing, brazing, or welding. Deburring and light edge breaking – Breaking and removing sharp edges, such as those left by machining, is achieved with a pH neutral compound. Surface grinding and smoothing – Grinding paste is added to help smooth surfaces. Polishing – To create very smooth surfaces, polishing paste is added. Brightening – pH neutral compounds are utilized to create bright, shiny surfaces. Passivation and corrosion protection – For protection from oxidation and short-term resistance to corrosion, pH neutral and slightly alkaline compounds are effective. Oil compounds are utilized for long-term protection against corrosion. By using several compounds, multiple tasks such as cleaning/degreasing, pickling, and drying or polishing, brightening, passivation, and drying can be combined into a single, fully automatic process. Rosler washing and drying system Operation Benefits In addition to the elimination of media costs and ability to use successive compounds and achieve various processes in a single machine, part-on-part mass finishing benefits include: Compact, space-saving designs since no additional space is required for a separate dryer. Simple material handling due to the elimination of work piece transfer between finishing machine and dryer. Fully automatic operation with suitable work piece loading and unloading equipment. No media issues such as lodging, chipping, or separation because no media is used. Batch operation with complete machine unload, eliminating the risk of parts getting mixed up. Different processing modes for different applications. Flow-through modes open drain valves allowing process liquid to flow straight through the machine. High water level modes close drain valves to retain process liquid in the machine. Use of multiple types of compound in one single process including acidic, pH neutral, and alkaline compounds as well as grinding and polishing paste. Standard Machinery Rosler developed special WTA rotary vibrators especially for part-on-part processing that not only allow running the finishing/washing process, but also the subsequent drying stage in one single machine. Rosler WTA Rotary Vibrator with drying system Besides WTA rotary vibrators, Rosler also offers centrifugal disk finishing machines that allow part-on-part cleaning/washing and drying in a single machine. Both machine types allow the complete unloading of a batch of finished parts to take place either by tilting the work bowl or by activating an unload gate in the bottom of the work bowl. Future posts in the part-on-part mass finishing blog series will compare these machines and their applications. The Rosler Way The experts at Rosler are eager to learn more about your part-on-part mass finishing challenges in order to learn about your needs, develop a solution, and deliver results. We are confident that Rosler can design a process and machine to fit your needs and supply the most appropriate compound for your process. Contact us today to discuss your needs. The complete Part-on-Part Series includes: Part 1 – Utilizing Work Pieces as the Media. Part 2 – Rotary Vibrators Versus Centrifugal Disk Machines. Part 3 – Effective Finishing for Ammunition Work Pieces. Sign up for enews alerts to be notified of all Rosler blog posts!

Automotive Crankshafts, Part 1 – Cost-Effective Surface Improvement for Key Engine Components

Crankshafts are a key component of internal combustion engines, be it mass-produced engines for motorcycles and automobiles , engines for heavy trucks, off-high highway equipment, and even large ships. Crankshafts convert the reciprocating (up/down) movement of the pistons/connecting rods into a rotational movement that drives the wheels and allows a vehicle to move forward. Rosler Metal Finishing understands the vital importance of these engine components and has developed specific shot blasting and mass finishing machines to process these pieces to perfection. A crankshaft with connected rods and pistons Materials & Production Methods Considering that automotive crankshafts weigh around 40-60 pounds and rotate approximately 100 times per second, these parts are exposed to tremendous tensile, compressive, and shear stresses. In addition, combustion forces and piston acceleration in an engine can also cause significant vibration. Therefore, crankshafts must be made from tough, wear-resistant materials, usually high alloy carbon steel. Typical alloying elements are manganese, chromium, molybdenum, nickel, cobalt, or vanadium. The most common materials are AISI/SAE 4340, EN-30B, 4330-M, 32-CrMoV-13, or 300-M. Crankshafts are made by: Casting – The production of cast iron crankshafts is limited to cheaper production engines, for example, low-performance diesel engines with lower overall loads. Hot forging – Today the most common manufacturing method is hot forging at temperatures of 1,700 to 2,100° F. Compared to casting, forged cranks offer a higher strength with – at the same time – lower weights and somewhat more compact dimensions. Depending on the utilized steel alloy, forged crankshafts may have to undergo a heat treatment process in the form of tempering and quenching. This is generally done after forging, but sometimes also after machining. Complete machining from a steel billet – This method is quite costly and is predominantly used for motorsport and high-performance applications, never for high-volume engine production. A hot-forged crankshaft After forging or casting, crankshafts must undergo an intensive machining process that includes: Turning of the journals, sometimes also called crankpins. Drilling of the oil holes in the journals. Drilling of the balancing holes in the counterweights. Milling of the drive sprockets, etc. Surface Treatment Tasks The main surface cleaning/treatment tasks for crankshafts include: Blast cleaning after forging or casting. Shot peening after machining. Deburring after machining. Blast cleaning after forging or casting is required because the forging/casting/heat treatment process leaves a relatively strong layer of scale on crankshafts and other work pieces. Prior to subsequent production processes such as machining and micro finishing, the work pieces must undergo a blast cleaning process to create a surface finish of SA 3, i.e. a pure white metal surface without any scale residues whatsoever. Crankshafts before and after blast cleaning The high compressive, shearing, and tensile stresses that crankshafts are exposed to as a result of machining can be relieved significantly by shot peening. In this application, the peening process focuses on the journals, especially the bearing surfaces as well as the journal fillets and journal cheeks (counterweights). Crankshaft peening is usually done by air blasting with relatively fine steel media. Deburring after machining is required to smooth edges including those of counterweight cheeks, drilled balancing holes in the counterweights, milled drive sprockets, and, sometimes, drilled oil holes in the journals. It is extremely important that the bearing areas on the journals are not damaged. The deburring operation is frequently done by mass finishing. Crankshaft machining The Rosler Way Whatever type of engine your crankshafts are designed for, Rosler can develop equipment and a process to provide accurate and repeatable finishing results. We are proud to lend our surface finishing expertise to the automotive industry. Contact us today to discuss your unique challenges. The complete Automotive Series includes: Part 1 – Cost-Effective Surface Improvement for Key Engine Components. Part 2 – Shot Blasting Machines Designed for Crankshafts. Part 3 – Typical Mass Finishing Machines Used for Crankshafts. Sign up for enews alerts to be notified of all Rosler blog posts!

Manufacturing Industry Outlook

At Rosler Metal Finishing , we believe in helping our clients in many industries find a better way to finish and process their products. Part of our success comes from understanding their industry, their process requirements, and market drivers. Our friends at IndustryWeek are making our jobs easier when it comes to understanding market drivers. The top findings from their recent research The Future of Manufacturing: 2020 and Beyond include: Positive outlook for growth and sales Leaders are overwhelmingly positive about their business growth prospects. Nine out of 10 expect revenues to increase and more than half (58%) anticipate strong growth of 5% or higher per year over the next five years. More than two thirds (70%) of manufacturers expect to increase the number of people that they employ over the next five years. Fulfillment strategies shift towards build-to-order Over the next five years, manufacturers will continue to move away from make-to-stock and shift towards less inventory dependent build-to-configure and engineer-to-order fulfillment strategies. This shift will cause processes and company strategy to focus on agility. Companies will be required to quickly shift attention and resources to mitigate risks and fully capitalize on growth opportunities. Increased productivity tops manufacturers’ investment list Companies will invest billions of dollars in a wide range of technologies during 2020. Decisions on where to invest will depend on leadership priorities and objectives. Predictably, whether driven by new technology or process improvements, productivity tops the list. The top 5 new technology investment priorities include: Higher productivity Faster responsiveness to customer orders and requests Enhanced collaboration with customers and suppliers Enhanced market intelligence More effective customer communication Market Volatility and rising material costs threaten growth he top challenges to meeting these strong growth expectations are market volatility, rising material costs, price reduction pressures, and increasing labor costs. To thwart such threats, according to Industry Week research, manufacturers are pushing hard to improve performance across a range of capabilities, starting with improving production processes, strengthening customer relationships and finding people with the right skills and experience. Rosler is your Secret Weapon With continued growth predicted across industrial sectors and a focus on improved process and productivity, Rosler is your secret weapon. The Rosler Group has been the experts in the field of surface finishing for more than 80 years and offers the most extensive portfolio in the world of mass finishing systems, shot blasting, consumables and services. The job of our specialists is to design a system for your finishing process, or a complete production line. We will provide support throughout your machine’s lifetime; from the planning phase, all the way to after-sales support and service. Our technology management team works with you to develop the perfect finishing process, precisely tailored to your work pieces. https://youtu.be/E7OQkfEXc8Y At Rosler, finding a better way is our goal. 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 surface finishing needs are, you can count on Rosler Metal Finishing to find a better way. Contact us today to start the conversation.

Aerospace, Part 3 – Drag Finishing for Airbus Helicopters

Mass Finishing – Are You Ready to Meet Customer Demand in 2020?

Updating a process to meet increased production demand is a cost-effective way to not only improve your processing times and results, but also increase and prolong your equipment’s usefulness. Let’s say production has been steadily building over time. How do you know if it’s time to evaluate the process for improvement? Mass finishing experts suggest examining the final finish accomplished by the process and its ceramic or plastic media and compound usage. Processes in need of optimization will not achieve the desired finish in an acceptable timeframe and will use more media and compounds than necessary. Increasing production demands without reconsidering the process can trigger finishing issues and lead to extra processing time and expense as well as rejected components. As more parts are processed, media begins to wear more quickly. As the media to component ratio decreases, part-on-part impingement is likely to occur and damage surfaces. In these cases, a more aggressive media with a higher cutting ability may solve the problem by producing the desired finish in a shorter cycle time. By lowering cycle times, the required media to component ratio can be achieved eliminating part-on-part contact and ineffective deburring. A process-oriented, experienced manufacturer such as Rosler can help you evaluate your current media type, workpiece properties, process time, and results to suggest an alternative media for optimized performance. Reactive Problem Solving Not all finishing problems are a result of increased production. An increase in processing time and scrap parts, poor finish, using too much water, and creating too much foam can also signal processing issues brought on by other known or unknown causes. If you’re not getting the desired finish on your components, reviewing the mechanics of the machine should be your first step. Meeting with a Client to Discuss a Process, Consumables, and Improvements Mass finishing experts suggest reviewing the machine to answer the following questions: Are the drains clogged? Has the movement of mass in the machine changed? Is the water/compound mix flowing properly? Are there bad valves or plugged compound valves? Is the liner intact or is a tear creating a dead spot where media is trapped? If the machine itself and its mechanics check out, the process should be examined carefully to identify an area in need of optimization. Process-related concerns include media that has glazed over and the presence of excess foam in the machine and/or too much water trapped by clogged drains. Evaluating mechanical and process efficiencies will not only help identify process problems, but also reduce processing costs. For example, maintaining the correct compound usage will reduce unnecessary consumption and ensure that components are processed more efficiently and with fewer rejects. A Learning Experience Mass finishing is an art and a science. No one knows that better than Rosler. When you lose track of that balance, mistakes are bound to happen. Whatever your process optimization needs are, you can count on Rosler Metal Finishing to find a better way. Contact us today to start the conversation.

Aerospace, Part 2 – Innovative Finishing for Aerospace components

The aerospace industry demands high repeatability and adherence to strict production tolerances. As we discovered in Aerospace, Part 1, Rosler Metal Finishing’s surface finishing technology delivers the precision needed for aerospace components both large and small. For complicated gear components, we turn to our drag finishing systems for exact results every time. Small to medium size structural aircraft parts Characterized by its sturdy design and numerous technical features, Rosler Metal Finishing’s drag finishing systems are ideal for high value and sensitive parts such as aerospace components that cannot touch each other during the finishing process.

A Year in Review – Top Blog Posts from 2019

At Rosler, we believe in helping our clients in unique markets find a better way to finish and process their products. According to Grand View Research, Inc., the global structural steel market is expected to reach USD 140.4 billion by 2025. It is projected to expand at a CAGR of 5.6% during the forecast period. Increasing construction spending in emerging economies is projected to drive the demand for structural steel. Maybe that’s why our top posts this year included a series on Structural Steel. Enjoy the following recap. 5. Optimal Media Mix, Part 1 – Identifying and Maintaining Proper Levels The best mass finishing equipment is useless without the proper media. That’s why the experienced engineers at Rosler Metal Finishing pair their quality equipment with the right type and amount of media to achieve consistent results. Media comes in all kinds of shapes and sizes Understanding how your machine, the work pieces it is finishing, and the selected media will interact is key to delivering an optimal finish each cycle. Doing so requires understanding why media levels are important, determining and tracking levels, and evaluating media consumption to avoid issues. Read more about identifying and maintaining proper levels with your media levels. 4. Structural Steel FAQ, Part 7 – Comparing Commonly Used Blast Machines Steel construction and steel trade , shipyards and ship building , and heavy equipment and machinery building rely heavily on specially designed shot blasting machines to prepare their components. Rosler Metal Finishing expertly designs shot blasting machines for these industries and others to descale, clean, and prepare structural steel for surfaces for end-use. The particulars of each machine largely depend on the size and shape of the specific components in need of preparation. This installment of our Structural Steel FAQ series answered: What are the most commonly used blast machines for structural steel surface preparation and how do they compare? Learn more about the commonly used blast machines for structural steel surfaces. 3. Structural Steel FAQ, Part 4 – Evaluating the Presence of Dust As an expert in the surface finishing industry, Rosler Metal Finishing knows that all the expertise in the world won’t do any good if the surface of the work piece is not properly prepared. When it comes to structural steel, we receive many frequently asked questions about preparation. This installment of our Structural Steel FAQ series answered: How is the presence of dust on shot blasted structural steel components evaluated? Learn more about how to evaluate the presence of dust. 2. Using Vibrascope to Measure Amplitude V. Frequency in Vibratory Bowls Example of vibratory drive 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, if it’s too low, can create a lackluster finishing results and longer processing times. If too high it can cause unnecessary wear and tear on the machine. Read more on using vibrascope to measure amplitude v. frequency in vibratory bowls. 1. Structural Steel FAQ, Part 3 – Evaluating Rust and Mill Scale Pre- and Post-Blast Surface preparation can account for up to 40 percent of structural steel painting and repainting jobs. As Rosler Metal Finishing’s Structural Steel FAQ series has already established, the life of anti‐corrosion coatings on a steel surface depends to a large extent on how thoroughly this surface has been prepared for painting. Application of anti-corrosion paint in a preservation line blasting system Properly evaluating the surface of structural steel surfaces for coating before and after shot blasting will help balance the cost of preparing, repairing, and monitoring structural steel throughout its impressive lifespan. This installment of our Structural Steel FAQ series answered: How are rust and mill scale evaluated pre ‐ and post ‐ blast? Learn more about how rust and mill scale are evaluated pre- and post-blast. 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 surface finishing needs are, you can count on Rosler Metal Finishing to find a better way. Contact us today to start the conversation.

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Procesontwikkeling is meer dan de som van systemen

UW PARTNER Wij maken van onze oplossingen úw ding Focus op oppervlaktetechniek – met oog voor het totale proces Ideale oplossingen zijn meer dan de som van installaties, procesapparatuur en bewerkingsprocessen: ze moeten passen in het totale proces van de klant en rekening houden met de bedrijfsspecifieke waardeketen en productieomgeving. Daarbij willen wij de oppervlaktebehandeling zo soepel mogelijk en met weinig logistieke en personele inspanning in de productieketen integreren. In een eerste stap inventariseren onze deskundigen uw productieomstandigheden en verwachtingen ter plaatse en leggen de resultaten vast in gestandaardiseerde vragenlijsten. Op dat moment weten wij al of we u naast de pure oppervlaktebehandeling nog andere processtappen kunnen aanbieden, bijvoorbeeld op het gebied van onderdelenreiniging, proceswaterbehandeling of procesautomatisering. Onze ambitie is duidelijk: wij ruimen moeilijkheden uit de weg, voordat ze problemen worden en houden rekening met alle eventualiteiten. Vervolgens is het een kwestie van maatwerk bij de eigenlijke oppervlaktebehandeling. Al vele tientallen jaren vertrouwen wij hierbij op het betrouwbare en beproefde werk van onze experts in de CEC's. Moderne digitale hulpmiddelen zoals simulatietechnologie stellen ons nu ook in staat om complexe en tijdrovende testreeksen te verkorten. Met name in de straaltechniek kunnen wij met behulp van digitale tweelingen echte processen volledig overbrengen naar de virtuele wereld en zo de kosten voor het vinden van een proces aanzienlijk beperken – en tegelijkertijd de doeltreffendheid verhogen. Om u een aanbod op maat te kunnen bieden, maken wij gebruik van talrijke analoge en digitale middelen, die wij bundelen in de process engineering. Bijzonder interessant wordt de process-engineering, als de stappen voor en na de oppervlaktebehandeling volledig geautomatiseerd worden. Op het raakvlak van robotica en oppervlaktebewerking hebben we bij Rösler de afgelopen jaren nieuwe standaarden gezet, met name in de glijslijptechniek en kunnen we nu de hoogste automatiseringsgraad op de markt aanbieden. Daarbij benutten we de synergieën van een onderneming die wereldwijd actief is in onderzoek en ontwikkeling: voor de volledige automatisering van productielijnen werken wij samen met onze collega's van Rösler France, die gespecialiseerd zijn in robotica en automatisering. Dankzij onze decennialange ervaring in oppervlaktebewerking weten wij dat alleen holistisch uitgedachte oplossingen werken – en wij kunnen deze doelgericht realiseren door gebruik te maken van de kracht van de wijdvertakte Rösler Group. Perfecte resultaten – die perfect passen bij u. Uw onderdelen in de beste handen - kijk zelf maar! Aanvraag verzenden

Procesmedia

DRY ELECTROPOLISHING Consumables Perfect electrolyte mixtures for dry electropolishing Our surface refinement experts precisely adapt the electrolyte granules to your equipment and your process. In this respect we focus on three essential factors: Material, required finish and work piece geometry. Generally, the following metals and metal alloys are suitable for dry electropolishing: Aluminum, cobalt-chrome, copper alloys, nickel alloys, titanium alloys, steel and carbide metals. Key factors for matching a suitable electrolyte medium to the respective metal are the metal composition, its density and hardness. In our main Customer Experience Center we stock a wide variety of media. This allows our dry electropolishing experts to perfectly match the medium to the metal, respectively, metal alloy that you are using in your production. In the next step we define, jointly with you, the desired finishing quality and adapt the process parameters to these required results. Along the way we ensure that the results are consistent and repeatable, the process runs efficiently with short cycle times and, above all, is gentle to the work pieces. Of course, the special design of our machines guarantees that these results are consistently achieved. They allow stable and precise surface finishes, irrespective of the size and shape of the work pieces. The overall process safety and stability is ensured by our versatile submersion and projection systems and the optimal flow of media and electrical current over the work piece surface. All these features guarantee perfect results! Overview over the available electrolyte materials The DLyte systems can be operated with dry and gel-type electrolytes. Dry, macro-porous electrolytes are generally more effective and can quickly smoothen rough surfaces. But they are more aggressive and can easily create burn marks on the work pieces. Gel-type electrolytes work more gently, because they are augmented with an oil suspension containing tiny particles. The oil suspension protects the work piece surface during the finishing process. Size and shape of the electrolytes Depending on the work pieces and the required surface finish, the users can choose from a range of different sizes and shapes of electrolyte granules. Dry electropolishing processes are particularly effective when they are run with multiple electrolyte particles in different sizes and shapes. Such a particle mix guarantees that the media reaches surface areas that are difficult to access. This results in a highly homogeneous and thorough finishing process. Gel-type electrolytes vs. dry electrolytes The electrolytes have not only different shapes and sizes, but they are also available in different physical conditions, for example, with different degrees of elasticity. Dry electrolytes generally work faster. But because of their poor flow characteristics they tend to leave burn marks on the work piece surface. Because of the cushioning effect of the additive, characteristics are gentler on the work piece surface and, overall, they produce higher-quality surface finishes. For processing of hard metal components mainly gel-type electrolytes are utilized. Chemical composition In order to achieve high-value finishing results, minimize the metal removal rate and maximize productivity, the adaptation of the acid concentration to individual electropolishing tasks is indispensable. Because the composition of electrolyte materials can be easily adapted to specific finishing tasks and industry standards, the DryLyte technology offers efficient and versatile solutions to a broad range of surface finishing applications. You want only the best for your surface? We will gladly help you! Aanvraag verzenden