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Intelligent solutions for efficient, automated plastic de-flashing

To further optimize product quality, productivity and manufacturing capacity, a leading supplier of injection-molded plastic components decided to decommission its existing shot blast machines and replace them with new ones. The company chose de-flashing solutions from Rösler: A RWS 1200 system that can be easily integrated into manufacturing cells and allows the consistent, automatic de-flashing of single work pieces. For processing complete batches of work pieces produced in bulk, a tumble belt blast machine, model RMBC 1.1-S, was selected. Since this machine allows surprisingly high batch volumes and short cycle times, it replaced three shot blast machines, which were previously used for the same de-flashing operation.

Lower costs, improved quality and absolutely consistent finishing results

To ensure the optimal function of artificial hips in a patient’s body, certain surface areas on the hip stem must have different finishes. For example, the neck area of the stems requires a very smooth, polished surface. Recently, a manufacturer of precision components replaced a combined manual grinding / electropolishing operation with a fully automated two-stage mass finishing process. The drag finisher R 4/700 SF from Rösler allows the simultaneous, precise finishing of twelve hip stems in one single operation. This resulted not only in significant cost savings and lower cycle times but also in a drastically improved quality and absolutely consistent finishing results. Since 20 years, the MBN Präzisionstechnik GmbH, located in the Austrian town of Pottendorf, has been specializing in the manufacture of machined precision components and assemblies. The company’s main focus is on the production of orthopedic implants and surgical instruments made from titanium and stainless steel. MBN Präzisionstechnik, certified according to DIN 13485, is not only equipped with ultra-modern machinery, including laser marking systems, but has also clean rooms for the coating and germ-free packaging of its products.

Highly automated shot blasting solution for transmission components in E-vehicles

For the expansion of its transmission production facility for electric vehicles a German automotive supplier purchased a new continuous feed blast machine from Rösler that includes fully automatic work piece handling. The customer chose the Rösler equipment, because it offered a high productivity, is easy to maintain and has a long service life. Excellent experience with a practically identical shot blast machine that has been running at the OEM since 2016 also played a role in the decision making process.

Non-Foaming Plastic Media Optimizes Finishing Process

While the optimization of mass finishing processes mostly focuses on the machinery utilized, Dörfler & Schmidt Präzisionsfinish GmbH (Dörfler & Schmidt) has shown that a simple shift such as using a different media can create significant process optimization. By switching to a new, non-foaming plastic media from Rosler , the post-processor achieved improved process stability, productivity, and efficiency. Meeting Varied Needs Founded in 1998, Dörfler & Schmidt offers a wide range of surface finishing including deburring , edge radiusing, surface smoothing and polishing , creating matte and textured finishes, descaling , and cleaning . The family-owned business located in Kammerstein, Bavaria, works with automotive , machinery building, electronics, medical engineering , jewelry , and a variety of consumer goods customers. “We have to deal mostly with requests for deburring and edge radiusing,” said Dörfler & Schmidt Management Assistant Felix Dörfler. “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 while jewelry and accessories must have an optically pleasing finish.” Work piece materials range from metal, plastic, and ceramic to glass and wood in dimensions as little as a fraction of an inch (a few mm) up to 25 in (60 cm). Working with a Proven Partner Dörfler & Schmidt operates 33 different machines capable of handling a broad range of different mass finishing and shot blasting technologies. “To handle various work piece materials, we employ different process water cleaning and recycling systems,” Dörfler said. “For this purpose, we are utilizing five centrifuges , which, like the overwhelming majority of our mass finishing equipment, were supplied by Rosler.” When it comes to consumables , Dörfler & Schmidt primarily uses Rosler products as well. “The consistently high quality of the Rosler media and compounds, as well as the excellent process development support and optimization by their Customer Experience Center , are just a few reasons why we’ve relied on solutions from Rosler right from the beginning,” Dörfler said. The Situation “For the deburring and edge radiusing 40-mm-long stainless steel wire segments, we need an excellent grinding performance with a high metal removal rate,” Dörfler said. “However, foaming during the finishing process created a buffer between the work pieces and the media, reducing the grinding effect. “Therefore, the desired finishing results could no longer be achieved within the prescribed cycle time,” he said. In addition to Prolonged cycle times and an inability to separate media from finished work pieces after processing, the foaming issue was even carried over to the process water cleaning system, where foam seeped out of the centrifuges, soiling the system itself and the immediate environment. A Smart Solution The extent of foaming issues largely depends on the hardness of the process water and can often be remedied with special additives. When the company’s Rosler Sales Agent learned of the problem, he recognized that additives weren’t effective and suggested the newly developed “N” series of non-foaming plastic media from Rosler. Dörfler & Schmidt subsequently joined a select group of companies who tested the new media series. Since the non-foaming media version is identical to standard plastic media in identical shapes, sizes, and grinding performances, it could be swapped in without finishing process modifications. The Results More than a year later, Dörfler & Schmidt is still using the non-foaming media. Impressive results are achieved within the prescribed cycle time and separation issues have also been resolved. The media switch also greatly simplified the monitoring of the finishing process. Eliminating the need for reprocessing significantly improved the process’ overall cost-efficiency and extended the usable life of the process water, reducing the consumption of additives and contributing to increased sustainability. “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,” Dörfler said. “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.” The Rosler Way All standard Rosler plastic media varieties have been available in non-foaming “N” versions since 2021, adding to the more than 15,000 equipment and consumable products we offer. Contact us today to discuss your mass finishing challenges and our solutions!

Wet Blasting Equipment & Media, Part 5 – Careful Media Selection, Additive Use Impact Results

Wet blasting and dry shot blasting often use similar media to achieve the desired processing result. Unlike dry blasting that only uses a solid abrasive media, wet blasting processes use a slurry of water with the shot blasting media. This greatly cushions the impact energy on the work pieces, providing gentler, yet effective results for delicate work pieces. The achieved surface finish and appearance will also differ between wet and dry processes, even when the same media type and size are used. With more than 80 years of experience worldwide, Rosler can supply both the machines and media best suited for your wet blasting needs. Common Media Types As long as it is heavier than water and not water soluble, practically any media used for dry blasting can be used for wet blasting. It is important to consider the usefulness of the media compared to its cost. While a cheaper or longer-lasting media may be available, it may also require additional processing time to accomplish the desired surface finishing. Selecting the most appropriate media for your process requires balancing initial costs with overall results. Common types of wet blasting media include (top, from left) brown, white, and pink fused aluminum oxide; glass beads, ceramic beads, (bottom, from left) stainless steel shot, stainless steel grit, and polycarbonate beads. The most common wet blast media include: Brown, white, and pink fused aluminum oxide – Widely used for blast cleaning, this media type’s hardness makes it ideal for surface cleaning and paint preparation. Glass beads – Useful in wet cleaning and light peening applications, glass beads can also be used for light deburring and cosmetic blasting. Ceramic beads – This media’s high bulk density produces a higher impact intensity than glass beads and is useful for general surface cleaning and shot peening. The spherical beads provide a bright matte finish. Stainless steel shot – While useful in special cleaning and shot peening applications, this media type is not suitable for non-ferrous, soft metals. Stainless steel grit – The high bulk density and angular shape of this media produces an excellent cleaning effect, but is not suitable for non-ferrous, soft metals. Polycarbonate beads – This media is useful for very gentle cleaning applications and cosmetic blasting. Water Additives Rosler offers a wide selection of additives and compounds. The addition of certain chemical additives to the process water will support the wet blasting process and help extend the usable life of the process water. Popular additives in wet blasting processes include: Degreasing compounds – These surfactants chemically augment the mechanical cleaning effect of the wet blast process. They are only applicable when the work pieces are covered with grease or oil. Heavy contamination must be removed before wet blasting. Corrosion protection compounds - Such compounds provide temporary corrosion protection for a few days on ferrous work pieces. Biocides – These additives prevent bacterial contamination of the process water/slurry. During downtimes and inactivity such as the holidays or weekends, bacteria grows more easily. The addition of a biocide prevents such contaminations and allows process water to be used for longer periods of time before being replaced with fresh water. Flocculants – Used for augmenting the cleaning effect of centrifuges, flocculants aid in the removal of contaminants from the process water by encouraging contaminates to “floc” or group together, making the larger pieces of debris easier to remove for the system. Water hardeners - If very soft water is used (< 70 mg/L or 4.2 grains per gallon), foaming in the wet blast machine and the filtration system can become an issue. In such cases, a water hardener is useful in eliminating and/or avoiding issues. The Rosler Way As the utilization of wet blasting increases, Rosler reminds manufacturers to review their traditional, dry shot blasting applications and consider if wet blasting could provide additional efficiencies, reduced costs, and better results. We have extensive experience in wet blasting. Whatever your challenges are, we are confident that we can deliver a solution. Contact us to discuss your needs today! The complete Wet Blasting Equipment & Media series includes: Part 1 – “Machines Range in Complexity, Uses.” Part 2 – “Technical Components Combine for Systematic Success.” Part 3 – “Maintain Slurry Concentrations for Finishing Consistency.” Part 4 – “Internal Cleaning, Rebuilds Prolong Machine Lifetime.” Part 5 – “Careful Media Selection, Additive Use Impact Results.”

US giant Wheel Pros purchases 41 Rösler wheel finishing machines

Torq Thrust – an automotive wheel model developed in the 1960s by American Racing – is the most famous and most copied wheel design of all times. And it has not lost any of its attractive appeal. In 2008 Wheel Pros, a leading manufacturer and distributor of top brand wheels took over the brand and in 2020 decided to “reshore” the production from China back into the United States. For this purpose an entirely new production line was set up in Auburn, Alabama. During his time as owner of the competitive brand MHT, now also a part of the Wheel Pros group, the vice president for marketing at Wheel Pros had a highly positive experience with Rösler. Therefore, he recommended this surface refinement specialist as partner for the surface finishing of around 50,000 wheels per year. A major requirement was that the cast aluminum wheels with diameters from 15 to 20 inches and widths between 7 and 9 inches are finished fully automatically. Another demand was that the mechanical process achieved an absolutely repeatable high luster finish comparable to the previous manual polishing operation within relatively short cycle times.

Linde MH relies on a sturdy foundry version of continuous feed spinner hanger blast machine

Linde Material Handling (MH) is a globally leading supplier of fork lift trucks and warehousing equipment. The company also provides technical solutions and services in the field of intralogistics. With a sales and service network in more than 100 countries the company is represented in all major regions of the world. In Weilbach the material handling specialist manufactures the counterweights for its broad program of fork lift trucks. Taking advantage of the potential for optimization with a new shot blast machine Linde MH is continuously striving to improve its manufacturing operations. Therefore, a Linde project team and the Rösler Oberflächentechnik GmbH worked closely together to optimize the material flow and increase the overall flexibility of the shot blasting operation for different lift truck counterweights (in short LTCW). To fulfill the demand for a better utilization of the available space, Rösler developed a customized system around a continuous feed spinner hanger blast machine RHBD 22/27-F that is setting new standards in the foundry industry. Fully automatic and flexible operation within an integrated manufacturing system Within the scope of the newly laid out material handling process the raw castings are deposited in a specially reserved, clearly marked staging area in front of the inlet chamber of the blast machine. After an operator has manually positioned the castings and confirmed this step at the control panel, they are picked up by a power & free system for transport through the shot blast machine. For each work piece type specific shot blasting and transport parameters were defined and stored in the respective PLC programs. This ensures that after the shot blasting operation the LTCWs are perfectly clean with no traces of residual molding sand. At the same time they have a highly homogeneous surface roughness that displays the typical casting structure of the work pieces, even after they have been painted. All process parameters were established on the basis of a suitable operating mix of the selected blast media. Special foundry version of the shot blast machine RHBD 22/27-F In compliance with the customer requirements the new shot blast machine was installed at its designated location in the factory. In a very tight space, but easily accessible for maintenance, the return system for the mix of blast media and sand was placed below the shot blast machine. Also integrated into this system was the return of the molding sand carried into the work piece staging area by the LTCWs. For this purpose, the sand is guided to a cross-chute located in front of the shot blast machine. This cross-chute then carries the material to the sand transfer hopper that transports the sand from LTCWs at the staging area and the sand from the inlet chamber onto the return conveyor below the inlet chamber. The return conveyor transfers the collected sand to the central screening hopper below the blast chamber. At the outlet chamber of the shot blast machine a floor scraper returns any residual sand and blast media to the central screening hopper below the blast chamber. The screening hopper separates all sand clumps, burs and metal flashes and transfers them to a sturdy Z conveyor belt for discharge from the machine. The screening hopper transports the remaining sand/media mix to an elevator, from where it is carried to the highly efficient media cleaning system. This device, consisting of a dual stage magnetic separator and an air wash system, ensures a high cleaning efficiency, guarantees a trouble-free operation and minimizes the wear of the shot blast machine. After the LTCWs have been manually positioned in the staging area, they are picked up by the trolleys of the power & free work piece transport system and carried through the different machine sections inlet chamber, blast chamber and outlet chamber at certain indexing time intervals. The three-chamber design of the shot blast machine also helped to minimize the escaping of sand, blast media and dust into the immediate environment. At the center of the entire shot blast system is the blast chamber with five specially placed blast turbines. The chamber is made from wear resistant austenitic manganese steel, grade X120Mn12. For additional wear protection it is lined with 25 mm thick replaceable cast chromium plates. A large maintenance platform, easily accessible by stairs, greatly facilitates the required maintenance activities. All goals achieved! With the new Rösler continuous feed spinner hanger shot blast system the demands by Linde MH for a technically and economically optimized shot blasting operation & work piece handling could be fully met. The quality requirements for the LTCW components are fulfilled through precisely defined shot blasting parameters, optimized blast patterns and better wear characteristics. Overall, this resulted not only in a significant improvement of the shot blasting results, but the streamlined shot blasting and transport concept also increased the overall efficiency of the material flow in the factory.

Wet Blasting Equipment & Media, Part 4 – Internal Cleaning, Rebuilds Prolong Machine Lifetime

While highly effective in a number of applications and industries, wet blasting can be a messy process. Unlike dry shot blasting which produces dust, wet blasting generates a mix of media, dirt, and debris mixed with water mist. If this water/particle mix is not removed properly the machine itself may be soiled to the point that it cannot be used. Mist which escapes the machine can also cause health hazards to personnel and other equipment in the area. Rosler builds its wet blasting machines with usability and safety in mind, factoring in precautions and cleaning functions to prolong the machine’s use and ensuring a clean, safe work environment. Internal Cleaning Rinse systems flush out contaminants including dirt, broken down media, and oil from the blast cabinet. After each blast cycle the inside of the wet blast machine must be cleaned by completely rinsing it down with clean water. High-pressure spray nozzles are installed to rinse the wet blasting machine’s viewing window. During the blast cycle and as needed, high-pressure spray nozzles rinse off any dirt from the viewing window. Water mist from processing as well as the internal cleaning process is continuously removed from the blast cabinet by a suction fan equipped with a filter which removes contaminants from the water. Rebuilding Established Systems Blast machines are often a considerable investment for companies. When these highly specialized and high-investment pieces of equipment start to show signs of wear and underperformance, expert surface finishing companies such as Rosler can help prolong the life and effectiveness of your investment by repairing and rebuilding a machine instead of replacing it. Cost is often the biggest factor considered when rebuilding a blasting machine. Generally, rebuilds offer shorter turnaround times than buying a new machine. Rebuilds also come with the added benefit of not needing to integrate a new process since the process already includes a proven shot blasting process. The Rosler Way We have the experience and expertise to meet your wet blasting needs. Rosler partners with you to find a better way, the best machine, and the best finishing results. Contact us today to discuss your unique challenges. Previous posts in the Wet Blasting Equipment & Media series include: Part 1 – “Machines Range in Complexity, Uses.” Part 2 – “Technical Components Combine for Systematic Success.” Part 3 – “Maintain Slurry Concentrations for Finishing Consistency.” The final post will be: Part 5 – “Careful Media Selection, Additive Use Impact Results.” Sign up for enews alerts to be notified of new posts!

Millenia Technologies is the new sales and service partner of Rösler in India

With Millenia Technologies, the Rösler Oberflächentechnik has a new and strong partner for the Indian market at its side. Millenia already works for years in the field of surface treatment and has lots of experience in the finishing, cleaning and measuring of components to enhance surface textures. With the mass finishing and shot blasting solutions of Rösler, Millenia can perfectly complement their portfolio of bringing the most advanced surface technologies to different industries. We are looking forward to a good cooperation with Millenia Technologies and to serve the Indian market even better.

Automotive Manufacturer Partners with Rosler for Fast Processing, Long Wear Life

True to our “finding a better way…” motto, Rosler partnered with thyssenkrupp AG to create a continuous flow shot blasting operation for the fastest crankshaft forge shop in the world. World renowned for its drive trains, chassis, and automobile manufacturing equipment, the automotive division of thyssenkrupp AG significantly contributes to the technical progress and efficiency of motor vehicles. The thyssenkrupp Gerlach GmbH plant in Homburg, Germany, is a leading partner for the development of automobile engine components, offering a full-service package ranging from component design, prototype fabrication, and full-scale production. Developing a Solution To improve cost efficiency at its Homburg plant and to meet all customer requirements, thyssenkrupp AG installed its high-tech “production line 19” for forged crankshafts for engines with one to four cylinders in 2016. For this line, Rosler developed an innovative shot blast equipment concept known as the Rosler RKWS crankshaft shot blasting system . At the beginning of the manufacturing sequence, bar blanks are cut to length. They are then heated in an induction oven before being shaped in a 6,500-ton press. In the last step, the crankshafts undergo a blast cleaning process in a shot blast machine. Using a unique equipment concept for the final blast cleaning step, Rosler engineers created a system for handling different work piece sizes without time-consuming retooling of the work piece holders. This innovation helped reduce the cycle time to less than 10 seconds, which in turn allowed the manufacturing operation to be run in a continuous flow. The result of the comprehensive cooperation between thyssenkrupp AG, Rosler, and all the other partners created the fastest, most modern crankshaft forge shop in the world capable of producing a finished component for its customers every 7.5 seconds. Crankshaft after surface finishing Delivering Convenience & Longevity Our innovations go beyond world records to provide long-lasting value and dependability. The RKWS system was also designed for long life and easy maintenance. The three blast chambers and the work piece load/unload chamber are arranged in a circle around a rotary drive equipped with an asynchronous servo motor with an extremely high overload reserve. Blast media is accelerated and thrown by Rosler Gamma G blast turbines equipped with a unique Y-shaped throwing blades. Rather than being made of chilled iron castings typically used in conventional turbines, critical wear components of the turbines are made of forged tool steel. This results in a much longer uptime of the throwing blades whose curvature produces a much higher throwing speed than straight throwing blades. In addition, the symmetrical Y design allows the use of both blade sides. The combination of more wear resistant material and the blade geometry result in up to three times longer usable blade life. Another feature of the Gamma G turbines is their easy maintenance. Turning the blades around or exchanging them can be done from the top of the turbine housing without having to dismount the impeller, control cage, and the media inlet tube required with conventional turbines. The RKWS is equipped with 12 Gamma G turbines, each with an installed power of 22 kW. The turbines, evenly placed on the three blast chambers, are capable of throwing the large steel shot onto the entire surface area of the crankshafts with a speed of 80 meters per second. This results in a complete removal of forging scale and other surface contaminants. By utilizing highly wear resistant material for all components exposed to the large cast steel shot and the removed forging scale, the RKWS shot blast system’s external workings are protected from excessive wear. The three blast chambers are lined with wear resistant hardened steel. Media augers are made from special steel that is predominantly utilized in the mining industry. Technical characteristics of this material are its extreme toughness and its remarkable hardness of 600 Vickers providing it with a considerable structural strength. Planning Proactive Maintenance Thyssenkrupp AG’s “production line 19” processes the entirety of the company’s customer orders within 21 shifts per week, posing a considerable organizational challenge for the thyssenkrupp Gerlach GmbH maintenance department. In order to manage time for the equipment upkeep, the maintenance team utilizes a TBM (time-based maintenance) system. Within a pre-determined time span, a recurring time window is defined for all inspection and maintenance activities as well as any required repairs including the replacement of spare parts. The time management allows requisitioning all repair materials in advance and facilitates the effective assignment of the maintenance personnel at thyssenkrupp Gerlach GmbH in Homburg. Stocking Spare Parts Planning certainty for the entire manufacturing line along with consistently high product quality is a high priority at thyssenkrupp Gerlach GmbH. For this reason, essential wear and spare parts for all machines were determined jointly with the equipment suppliers and stocked on-site in Homburg. To define the specific requirements for the crankshaft shot blast machine, the customer relied on the experience of the Rosler service department. Based on the customer specifications, our service experts conducted a risk and wear analysis using an ultra-modern simulation of the blast media recycling process allowing them to determine the wear intensity for every single component. Based on the results of the analysis a comprehensive list of recommended spare parts was prepared including wear parts such as protective wear plates, etc. The Rosler Way Working with an experienced supplier is the best way to develop and maintain a shot blasting operation. From selecting the right type of machine for your needs to suggesting everyday actions to ensure repeatable results and extended uptime, Rosler develops lasting solutions. Contact us to learn how we can put our surface finishing expertise to work for you!