PRE-TREATMENT , SURFACE PREPARATION , DEGREASING & CLEANING
Innovative consumables for mass finishing operations
Simple steps to improve finishing results , sustainability and efficiency
When it comes to achieving the required quality of products by surface refinement , the mass finishing technology can be used for a broad range of different finishing tasks . With its comprehensive research & development activities the Rösler Oberflächentechnik GmbH continues to generate new technical highlights not only for the machine technology but also for the respective mass finishing consumables . Three recently introduced products make it possible to significantly improve the finishing results , the process consistency , the cost efficiency and sustainability of mass finishing operations . At the same time , they open the door for new applications , for example , the finishing of complex , cup-shaped work pieces .
The mass finishing technology can handle all kinds of surface finishing tasks ranging from the simple deburring / edge radiusing and surface grinding to high gloss polishing of mass-produced bulk goods and single components . It can even create special effects on the surface of the work pieces . Of course , like any other industrial processes , mass finishing operations must comply with all kinds of requirements such as high quality standards , process stability , work piece traceability and cost-efficiency . More recently optimal resource utilization and sustainability have become a focal point in numerous industries . And finally , the rapidly growing automatization and digitization of manufacturing operations also calls for specially adapted solutions for mass finishing operations . For decades the Rösler Oberflächentechnik GmbH has met these challenges with comprehensive research and development in the equipment sector as well as in the fields of process and automation technology and consumables . In this context a big advantage is that Rösler is producing all its consumables in-house . Rüdiger Böhm ,
The patented shape of the innovative MultiShape media significantly reduces the risk of media lodging in the work pieces . It also increases the stability , efficiency and sustainability of finishing processes with complex components . Moreover , the MultiShape media with its rounded surface areas allows the surface refinement of work pieces , which to-date could not be handled by mass finishing at all or only with very complicated operational setups .
global R & D manager at Rösler , explains : „ We study the technical trends and requirements in numerous industries and markets extensively . Our findings are then systematically utilized for the development of innovative products to provide a significant incremental value to our customers and to expand the application range for the mass finishing technology ”.
MultiShape – a unique media shape that makes the impossible possible
Such an innovation is the new MultiShape ceramic media . Compared to all other products currently available in the market , this media has a patented shape without any flat , parallel surface areas . On the one hand this unique design prevents media lodging in the work pieces , which can occur particularly in case of complex work pieces . Such lodged media can severely affect the finishing process and must frequently be removed by hand . On the other hand , the shape with its rounded surface areas allows the surface refinement of work pieces , which to-date could not be handled by mass finishing at all or only with very complicated operational setups . This includes components with difficult-to-reach surface areas like tight radii , undercuts , notches and slits , which can frequently be found in stamped and bent components . The unusual ceramic media also allows the effective and homogeneous finishing of external and internal surface areas on tube segments and cup-shaped components like housings and deep drawn parts .
Compared to traditional ceramic media , the new product is also characterized by a faster and more dynamic motion of the work piece / media mix and a higher material removal rate . This results in up to 10 % shorter finishing times . Therefore , the new media represents a significant contribution towards higher productivity and cost-efficiency . Another important attribute of the MultiShape media are its uniform wear characteristics . This excellent shape retention feature allows a longer media use , which is positively affecting the operating costs . The grinding intensity can be adjusted to the respective finishing application through different ceramic compositions .
Mass finishing without foaming – increased process stability , efficiency and sustainability
Unwanted foam is a common phenomenon in mass finishing processes with plastic media , even with foam-reduced media versions . Foaming can be problematic because , acting as a buffer between the work pieces and media , it reduces the grinding performance and material removal rate . This can diminish the process stability , and the
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40 DECEMBER 2021 twitter : @ surfaceworldmag