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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. Rösler 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 will answer that question: What are the most commonly used blast machines for structural steel surface preparation and how do they compare?

Machine Insight: RSA 1500 Indexing Satellite Table Air Blast System

Rösler’s RSA 1500 offers compressed air blasting technology in an indexing satellite configuration. This system is ideal for descaling, surface texturing, cleaning, deburring, de-sanding, creating homogeneous surface finishes, and shot peening.

Lower costs and higher productivity for shot peening processes

Shot peening, the “hammering” of work pieces with precisely defined blast media, is an indispensable operation in industries such as automotive and aerospace. By inducing a residual compressive stress into the work pieces, the shot peening operation substantially improves their long-term resistance against tensile and bending loads. The process is used for treating toothed, steering and transmission components, also for springs, drive- and crankshafts and all kinds of turbine blades. A significant advantage of the peening operation is that the component weight can be reduced without impacting its mechanical load capabilities. This is particularly beneficial in electric vehicles, because it increases their operating range and reduces their energy consumption. Due to changing work piece structures and shapes E-mobility frequently necessitates the alteration of manufacturing processes. Moreover, the customers are demanding significantly higher energy-, resource- and cost-efficiency. In other words, significant improvements in productivity and sustainability. Rösler can provide comprehensive support for such optimization projects.

Avoid Media Glazing to Prevent Process Inefficiencies, Breakdown

Media plays an essential role within a mass finishing process. Whether ceramic, plastic, if polishing or drying, optimal media mix and conditions must be maintained to produce precise finishing results. “Glazing” occurs when the surface of the media becomes contaminated with metal fines and other debris from the work pieces. As a result, the media becomes very shiny and frequently looks like a piece of aluminum, brass, steel, zinc, etc. Because glazed media completely loses its original surface properties, it no longer has any grinding effect. Instead, glazed media creates a sort of uncontrolled burnishing. It also retains dirt and other particles which are then deposited on the work pieces. The image above depicts (from left) media states include clean, heavily glazed, partially cleaned, and fully cleaned. Rösler has more than 60 years of media production experience. In that time we’ve seen—and corrected—countless examples of ineffective surface finishing as a result of media glazing.

Plastic deflashing Part 3 - Advantages and limitations of turbine and injection blasting

There are two main blasting processes available for deflashing plastic components, primarily made of thermoset and special thermoplastic materials: Turbine blasting, which is extremely effective over a large area, and highly efficient punctiform acting injection blasting. Both processes are also used in conventional blasting systems for metal processing. In contrast, plastic deflashing is a much gentler processing method, particularly due to the selection of non-abrasive blasting media. Which blasting process is selected for plastic deflashing depends on various factors. These include the production volume and the question of whether bulk material processing is possible or whether the parts are of a type that requires individual part processing. Another criterion is the question of whether the parts are to be partially or completely blasted and which blast media grain size and blast media speed are required.

Rösler becomes exclusive global sales partner for GPAINNOVA's DLyte Carbide Series for surface finishing of carbide cutting tools

Rösler Oberflächentechnik GmbH and the Spanish technology group GPAINNOVA are expanding their partnership: After Rösler has been the exclusive distributor of GPAINNOVA's DLyte Industrial Series for the German market for some time now, the world market leader Rösler will also take over the worldwide distribution of GPAINNOVA's Carbide Cutting Tools Series as well as the individual process development and service of the machines. In addition, GPAINNOVA is working closely with Rösler on the further development of the DLyte Carbide Series and the underlying DryLyte process.

Overcoming the shortage of skilled labor with smart shot blast solutions

In many industrial sectors the pronounced shortage of skilled labor is an essential obstacle for sustainable growth. With clever automation and digitization of manufacturing operations this problem can be partially overcome. When it comes to shot blasting applications, Rösler offers excellent equipment concepts for indexing continuous flow manufacturing operations. One such machine is the compact RWK 6/12-2 swing chamber shot blast machine. Equipped with automated work piece handling it can easily be integrated into linked manufacturing lines, requiring very little space. In addition, the furnished digitization software package from Rösler Smart Solutions provides complete process and cost transparency and minimizes the overall personnel requirements.

GPAINNOVA DLyte Pro 500

Surfaces with a high-gloss finish, as if polished by hand With its patented DryLyte technology for dry electropolishing, the Spanish technology company GPAINNOVA has set new standards for the high-gloss polishing of metallic workpieces. Rösler is the exclusive German sales partner for GPAINNOVA's DLyte systems and an expert in the field of dry electropolishing. The most powerful model in the DLyte machine series for polishing metallic components is the DLyte PRO 500.

Rösler PowerLine valve – the first blast media flow control based on AI

New preservation line placed into existing building containing an overhead crane

In order to meet customer demands faster and more efficiently, the Carl Spaeter Hamburg company expanded its range of manufacturing equipment with a preservation line KON 34/6-HD from Rösler that combines shot blasting and painting in one single system. It is designed to handle steel components, up to 3,200 mm wide, 400 mm high and a max. length of 21.2 meters. The line is equipped with two paint systems. Perfectly integrated into an already existing building containing an overhead crane, the new preservation line allows not only a higher material throughput but also improves the entire production flow resulting in shorter lead times.

R6/1000 SF Drag Finishing System & Medical Implants

Rösler is continuously searching for ways to improve the finishing technologies utilized within the medical industry. One of the most valuable solutions offered is the R 6/1000 SF Drag Finishing System which provides perfect mass finishing to orthopedic implants with its exact drag finishing technique.

Simulation of shot blasting machines and processes

In many industries shot blasting is an indispensable surface treatment technology. Apart from the goal of achieving the best possible results, customers always demand short cycle times, the lowest possible costs and minimal material input. Rösler fulfills these requirements, among other things, by utilizing ultra-modern simulation software. In addition, virtual models significantly reduce the time for engineering – especially for large, complex machinery – and ensure that the equipment is available within shorter lead times.

Orthopedic Implants – Mass Finishing Offers Medical-Grade Polishing | Part 2

Mass finishing is a highly versatile finishing technology used for a wide variety of different surface treatment operations including those in the medical industry. As a result, it is no surprise that mass finishing processes are utilized at practically every manufacturing stage for all kinds of orthopedic implants. With decades of experience, Rösler leverages mass finishing technology and develops equipment to meet the tight tolerances required for orthopedic implants.

Automatic loading and blast cleaning of sheet metal components without "teaching" requirement

When the OTTOSTAHL GmbH had to replace an old rotary table shot blast machine, the company insisted on short cycle times, high energy efficiency and relieving the personnel from strenuous and monotonous physical activities. These challenging demands were met by Rösler and the automation specialist Teqram with the universally usable rotary table Easy Shotblaster RDT 150, equipped with a stationary “intelligent” robot. This robot places the work pieces on the rotary table in a manner that optimally utilizes the entire table area without requiring any “teaching” operation.

R…DA Series of Linear Continuous Flow Vibratory Systems

Rösler offers several linear, continuous flow vibratory systems. The R...DA series is especially useful for finishing die castings, cast and forged crankshafts, clutch carriers, and more. These mass finishing machines can be interlinked with other systems and are highly automated. As a result, they are particularly useful in processing high volumes of all sizes of work pieces.