The document provides an introduction to mass finishing processes. It discusses how natural forces can smooth and polish stones, and how mass finishing machines replicate this using media and relative motion between parts and media. It describes the key elements of mass finishing, including the machine, media, compound, water, and how they interact. It also discusses batch and continuous processing, accessories like controls and dosing systems, and effluent collection needs. The overall document serves as a high-level overview of mass finishing concepts and components.

1. Introduction to Mass Finishing
Massfin
Present
ROSLER
leading company world wide
in the field of vibratory finishing
August 2010 Introduction Page 1

2. Introduction to Mass Finishing
Massfin
1.1 What is mass finishing
Nature showed us that stones can be transformed into smooth rounded
pebbles by constant grinding with water and sand.
„Intelligent“ media from Rosler have transformed this process into a
sophisticated operation.
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3. Introduction to Mass Finishing
Massfin
1.2 The elements of mass finishing
Water
Raw part
F in is h e d p a rt
Media
Compound Effluent
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4. Introduction to Mass Finishing
Massfin
1.3 The mass finishing process
In the work bowl of a vibratory finishing machine
the batch of
media, workpieces and water with compound
is put into motion.
This is causing
a relative movement
between
media and workpieces
This is causing
a grinding of media
on surfaces and edges
and removal of material.
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5. Introduction to Mass Finishing Massfin
1.4 The types of mass finishing operations
This simple principle
has been developed deburring radiusing smoothing
into an
all-round
and
polishing ball polishing
highly productive
technology of
surface finishing. cleaning degreasing descaling
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6. Introduction to Mass Finishing
Massfin
1.5 Mass finishing or shot blasting
Task Mass finishing Shot blasting
Deburring Burrs of all Only fine burrs and flashes
kinds
Radiusing Any required Very limited
radius
Surface smoothing Yes No
Polishing Yes No
Degreasing Yes Very limited
Cleaning Yes (slow) Fast
Descaling Yes (slow) Yes (fast)
Roughening No Yes
(prior to painting)
Shot peening No Yes
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7. Introduction to Mass Finishing Massfin
1.6 Saleable mass finishing products
Spares;
polyurethane Flocculation
relines compounds Finishing
Finishing compounds
equipment
Effluent treatment Grinding and
systems e.g. centrifuges Peripheral equipment polishing media
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8. Introduction to Mass Finishing
Massfin
2.The elements of mass finishing machinery
The machinery induces the mechanical energy
required to produce the relative movement
between parts and grinding/polishing media.
Mass finishing machines always consist
of a work bowl
containing the mass of parts
and grinding/polishing media.
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9. Introduction to Mass Finishing Massfin
2.1 The elements of mass finishing - types of machinery
Types of machinery
Vibratory
Centrifugal
Tubs
disk
machines Drag
finishing
Round Vibrators
machines
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Massfin
2.2 The elements of mass finishing - media
The media – either for grinding or polishing –
does the actual work
by
constantly rubbing against the parts
(RELATIVE MOVEMENT!)
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11. Introduction to Mass Finishing Massfin
2.2 The elements of mass finishing - media general
Rosler media consist of selected
abrasive materials like quarz,
aluminum oxyde and silica carbide
with precisely defined mesh sizes.
The abrasive materials are
imbedded in a ceramic mass or
in a mass of organic resins.
All media wear during the mass
finishing process
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12. Introduction to Mass Finishing Massfin
2.2 The elements of mass finishing - types of media
Types of media - Plastic media
- Ceramic media
- Porcelain polishing media
- Steel media
- Glass beads
- Anti-adhesion balls
- Corn cob drying and polishing granulate
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13. Introduction to Mass Finishing Massfin
2.2 The elements of mass finishing - media selection
• Desired grinding effect ?
• Desired rate of wear ?
• Is chipping of the media a problem ?
• Desired surface smoothness ?
• Danger of media lodging in the parts ?
• Grinding of inner parts contours required?
• How can media and parts be separated ?
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14. Introduction to Mass Finishing Massfin
2.3 The elements of mass finishing - compounds
Compounds are required
to support the mass finishing process:
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15. Introduction to Mass Finishing Massfin
2.3 The elements of mass finishing - job of compounds
Compounds are required
To dissolve
dirt and grease from the parts surface
To clean
the media to keep their „grip“
To remove
media and metal fines and dirt from the machine
To protect
The finished parts against corrosion and oxidization
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16. Introduction to Mass Finishing Massfin
2.3 The elements of mass finishing - types of compounds
Liquids Powders
Pastes
for
polishing
Effluent For recycling For shock degreasing
going with
to drain centrifuges For grinding support
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17. Introduction to Mass Finishing Massfin
2.4 The elements of mass finishing - water
Almost all
mass finishing processes are wet.
The process water
Serves as a coolant for the process
Absorbs potential dust
Dissolves and distributes the compound
Removes media and metal fines
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18. Introduction to Mass Finishing
Massfin
2.6 Interplay of components
Only if compound
water media
- type of machine
- amount of water
- type, shape and
size of media
- kind and amount
of compound
are well chosen,
optimal finishing effluent
results can be
achieved!
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19. Introduction to Mass Finishing
Massfin
2.7 The importance of trials
Mass Finishing is an empirical Customers
surface finishing problem
technology!
Precise definition
With most projects of finishing task
a successful sale is preceded
Processing trial
by a
successful trial
High probability yes Trial successful ? no
of getting the order
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20. Introduction to Mass Finishing
Massfin
3. Effluent treatment
Clear Solutions
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21. Introduction to Mass Finishing Massfin
3.1 Why must mass finishing effluents be cleaned ?
Effluent from mass finishing machines
contains:
- Abrasive fines from chips
- Abrasive fines from work pieces
- Detergents from compounds
- Oil and dirt from work pieces
- Metals in solution from work pieces
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22. Introduction to Mass Finishing
Massfin
3.2 The major cleaning systems
Flocculation is needed,
if effluent is to
be discharged to drain.
Centrifuges can be used,
if effluents
are recycled
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23. Introduction to Mass Finishing
Massfin
3.2.1 Flocculation systems
Work-
pieces Compound Flocculation is the standard method,
if effluent is to be discharged
to drain.
Finishing
machine
Buffer tank
Flocculation
compounds
Flocculation
reactor
Clear
water
Filter press
Sludge
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24. Introduction to Mass Finishing Massfin
3.2.1.1 Advantages / Disadvantages of flocculation systems
Advantages
• effluent clean enough
to go to drain
• can also be used for
special finishing
applications
Disadvantages
• high capital cost
• high water/compound
consumption
• high operating cost
• very limited recycling
possibilities (only
water and only 70%)
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25. Introduction to Mass Finishing
Massfin
3.2.2 Centrifuges
Work-
Compound
Centrifuges, the ideal tool for
pieces
recycling!
Finishing
machine
Effluent
tank
Centrifuge
Clear water
Sludge
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26. Introduction to Mass Finishing Massfin
3.2.2.1 Advantages / disadvantages of centrifuges
Advantages
• relatively low capital
cost
• less water/compound
consumption
• less sludge
• less space requirements
• easy operation
• no chemicals required
for effluent treatment
Disadvantages
• not universally usable
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4. Mass Finishing machinery
Robust
Powerful
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Massfin
4. Types of Mass Finishing Machinery
There are two types of classifying
Mass Finishing equipment:
4.1 Type of relative movement between parts
and media
4.2 Type of parts processing (batch or continuous)
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29. Introduction to Mass Finishing Massfin
4.1 Generation of relative movement between parts and media
The following types of movement are available:
A. Vibrators
- Circular vibrators
- Trough or tub vibrators
B. Centrifugal Disk Finishing
machines
C. Drag Finishers
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Massfin
4.1.3 Circular Vibrators
Components: machine frame with springs
- circular workbowl
- vibratory drive (flange motor)
- separation device
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31. Introduction to Mass Finishing
Massfin
4.1.4 Tub Vibrators
Components:
- machine frame with springs
- rectangular work bowl
- vibratory drive (either foot motor
or electr. motor with imbalance units)
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32. Introduction to Mass Finishing Massfin.ca
4.1.4 Centrifugal Disk Finishing Machines - principle
The high performance
centrifugal disk
machines contain
a rotating disk (spinner)
as the bottom of a
cylindrical workbowl
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33. Introduction to Mass Finishing Massfin.ca
4.1.4 Centrifugal Disk Finishing Machines - modular systems
Stand alone machines
without loading or
screening systems
Components:
- machine frame
- workbowl with spinner
- spinner drive
- tilting/unloading device
(either manual or
hydraulic)
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34. Introduction to Mass Finishing Massfin.ca
4.1.4 Centrifugal Disk Finishing Machines - FKS
FKS machines
with flanged-on
screening machine
- Tilting mechanism for work bowl
and screening machine:
Gear motor
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35. Introduction to Mass Finishing Massfin.ca
4.1.4 Centrifugal Disk Finishing Machines: batch systems
Components: 2
1- hydraulic loader
1
2- workbowl with
spinner
3- separation
3
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36. Introduction to Mass Finishing Massfin.ca
4.1.4 Centrifugal Disk Finishing Machines: batch systems
4- hydraulic tilting/
unloading device
5
5- intermediate hopper
6- screening machine 6
7
7- media return
conveyor
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37. Introduction to Mass Finishing Massfin.ca
4.1.5 Drag Finishing Machines
Components:
- circular work bowl
- Spinner with work stations
- Rotational drive for spinner
and work stations
- Lifting and lowering
mechanism for spinner
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38. Introduction to Mass Finishing Massfin.ca
4.2 Type of parts processing (batch or continuous)
In Mass Finishing applications we differentiate
between
two types of processing systems:
- Batch processing
- Continuous processing
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39. Introduction to Mass Finishing
Massfin.ca
4.2.1 Batch systems
A certain amount of parts and media (mainly
determined by volume) is filled into the work
bowl – or placed on fixtures – and processed
according to a pre-set processing time.
The processing time is determined by the
specific finishing objective and can last from a
few minutes up to 24 or more hours!
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40. Introduction to Mass Finishing
Massfin.ca
4.2.1 Batch systems
After completion of the finishing process the
complete parts batch Is removed from the work
bowl to be transported to the next station of the
manufacturing process.
Typical batch machines are: Centrifugal disk
finishing machines, Tub vibrators, Circular
vibrators
Circular vibrators are mainly used for batch but
can also be used for continuous operation.
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41. Introduction to Mass Finishing Massfin.ca
4.2.2 Continuous systems
Parts are continuously fed into the finishing
machine according to pre-set cycle times. They
travel through the machine more or less behind
each other.
Typical continuous systems
are continuous tub vibrators
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42. Introduction to Mass Finishing
Massfin.ca
4.2.2 Continuous systems
At the machine exit the finished parts are
separated from the media which is returned to
the finishing machine.
The finished parts are continuously transported
to the next station of the manufacturing process.
Typical continuous systems
are continuous vibrators
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43. Introduction to Mass Finishing Massfin.ca
5. Accessories
Rosler Surface Finishing Machines must be equipped
with certain basic accessories:
a. Electrical controls
b. Compound and water dosing systems
c. Effluent collecting and pump stations
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44. Introduction to Mass Finishing
Massfin.ca
5. Accessories – electrical controls
The range of Rosler electrical controls
reaches from simple switchboxes up to
- complex PLC- based control panels
- with touch panel and display screens
- and interface to the customer´s production
control system.
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45. Introduction to Mass Finishing Massfin
5. Accessories – electrical controls
Most control panels are equipped with frequency converter to
vary the speed of vibratory motors or rotary drive units (gear
motors).
For trouble shooting
our electrical engineers
can directly access the
customer‘s control panel
via modem.
This helps to minimize
downtimes!
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46. Introduction to Mass Finishing Massfin
5. Accessories- dosing systems
Dosing of the right amount of water and
compound is a pre- condition for successful
surface finishing
For recycling of the process
liquid different types of
dosing systems for
replenishment with water,
finishing compound and
flocculation compound
are required
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47. Introduction to Mass Finishing Massfin
5. Accessories – effluent collecting and pump stations
The effluent (water, compound, oil, metal and media fines)
coming from the finishing machine
must be collected and transported to the effluent treatment station.
Rosler collecting and lifting
stations consist of
- a tank for collecting the effluent
- float switches
- a stirrer to keep the solids in
suspension
- a compressed air diaphragm
pump or a electrical pump
The Rosler collecting and pump stations are designed to withstand
the abrasive wear of the metal and media fines in the effluent !!!
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48. Introduction to Mass Finishing Massfin
6. Auxillary equipment
Besides the actual Finishing Systems,
Massfin/Rosler offers a wide range of
AUXILLIARY EQUIPMENT
for
- material handling of the parts
- separation of parts from media
- drying of the processed parts
- safety, like noise protection
- washing of the parts and their corrosion protection
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49. Introduction to Mass Finishing Massfin
6.1 Material handling – hydraulic load and tip systems
Hydraulic load and tip
systems are required to
transfer the raw parts –
usually small bulk parts –
from the customer‘s parts
bins into the Rosler
finishing
machine
Rosler produces its own
range of hydraulic load and
tip systems with a
lifting capacity from
600 kg up to 1500 kg.
The load and tip systems are adapted to the
specific parts bins utilized by the customer
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50. Introduction to Mass Finishing Massfin
6.1 Material handling – vibratory hoppers
Vibratory hoppers are frequently used in combination with
hydraulic lift and tip systems:
- a hydraulic lift and tip systems transfers the raw parts – usually small
bulk parts -- from the customer‘s parts bin into a vibratory hopper
- the vibratory hopper feeds the parts into the Trowal finishing
machine
• Vibratory hoppers are powered
by a magnetic vibratory drive
system
• By adjustment of the frequency of the
vibratory drive (thyristor), an exact
dosing of parts into the Trowal
finishing machine is possible
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51. Introduction to Mass Finishing
Massfin
6.1 Material handling – vibratory hoppers
Massfin/Rosler produces/design its own range of vibratory hoppers with a
capacity from 800 kg/l up to 2000 Kg/l.
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52. Introduction to Mass Finishing Massfin
6.1 Material handling – conveyor belts
Conveyor belts are widely used for transporting raw and
finished parts as well as grinding or polishing media:
- transport of large parts – which cannot be handled by a hydraulic
load and tip system -- into the finishing machine
- transport of finished parts from the Rosler finishing machine to
the next processing station (e.g. dryer, washing machine, etc.)
- transport of grinding/polishing back into the finishing machine
Massfin/Rosler conveyor belts must be
• suitable for wet operation!
• acid – resistant and resistant
against oil
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53. Introduction to Mass Finishing Massfin
6.1 Material handling – conveyor belts
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54. Introduction to Mass Finishing Massfin
6.1 Material handling – back fill systems
Backfill systems are required to
gently
return finished parts back
into the customer‘s parts bins
Backfill systems are
hydraulically activated and
prevent high dropping
heights during the transfer
of the finished parts back
into the parts bin.
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55. Introduction to Mass Finishing Massfin
6.1 Material handling – handling and transport systems
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56. Introduction to Mass Finishing Massfin
6.1 Material handling – handling and transport systems
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57. Introduction to Mass Finishing Massfin
6.2 Separation systems
Mass finishing operations always require the
separation of media from the finished parts
Exception:
Part-on-part finishing!
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58. Introduction to Mass Finishing Massfin
6.2 Separation systems – integrated separation systems
Almost all circular vibrators have an integrated separation system.
Integrated separation systems
consist of
• a manually or pneumatically
operated separation flap
• a separation screen:
Usually the perforation in the
screen is such that the media
falls through the holes, whereas
the finished parts stay on the
screen and are transported
out of the circular vibrator!
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59. Introduction to Mass Finishing Massfin
6.2 Separation systems – integrated separation systems
Reverse screening
This is occasionally required, wenn the
PARTS ARE SMALLER THAN THE GRINDING/POLISHING MEDIA
Reverse screens
usually consist of a
tailormade double
deck design
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60. Introduction to Mass Finishing
Massfin
6.2 Separation systems – Magnetic separators
If the separation of media from the parts by simple screen is
difficult,
- because the parts have an unfavorable shape which could cause
them to lodge in the screen perforation
or
- the media and parts have a
similar size
a Magnetic Separator can be the
solution to such a problem!
Precondition for magnetic
separation:
Parts must be ferrous!
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61. Introduction to Mass Finishing Massfin
6.2 Separation systems – Undersize media classification
Undersize media must be removed
from the finishing machine, because
a. after reaching a certain size -- due to
their smaller mass -- they no longer
offer an adequate grinding effect.
b. undersize media have to be removed,
before they can lodge in the parts
There are 2 classification systems
a. permanent undersize screening in the
bowl discharge.
b. undersize removal during the
separation cycle by separate undersize
screen
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62. Introduction to Mass Finishing Massfin
6.3 Drying of finished parts
Mass Finishing is a wet process.
For this reason the finished parts coming from the finishing machine
must undergo a drying cycle!
Massfin – Rosler offers three types
of drying systems: • Vibratory dryers
- with drying medium
- with hot air
• Hot air belt dryers
• Rotary drum type dryers
- with drying media
- with hot air
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63. Introduction to Mass Finishing Massfin
6.3 Drying of finished parts – vibratory driers
Vibratory dryers with medium
Type RT Series
The induced vibration generates a
gentle roling movement of parts and
drying medium (e.g. Corn cob, wood chips).
The moisture on the parts is absorbed
by the heated drying medium.
The constant relative movement between
parts and medium has not only a drying
but also a polishing effect on the parts.
The RT – range consists of 4 models with a capacity of 2 to 15 cu/feet
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64. Introduction to Mass Finishing Massfin
6.3 Drying of finished parts – vibratory driers
Vibratory dryers with medium
RT Series
RT– dryers are mainly used for drying of small to mid-size parts
of relatively simple geometry and without any openings
where drying media might lodge
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65. Introduction to Mass Finishing Massfin
6.3 Drying of finished parts – vibratory driers
The following models of RT - dryers are available
Maximum parts
size Power of drive Power of heating Standard motor
Model Usable volume
(measured system system speed
diagonally)
.75 kW 2.3/4.6 kW
RT 150 Euro 2.0 cu ft 6.3 in 1500 rpm
1 Hp 4/6 Hp
1.5 kW
RT 250 Euro 3.0 cu ft 8.3 in 2.3/4.6/6.9 kW 1500 rpm
2 Hp
4/6/9 Hp
3 kW 6.6/12.2/16.5 kW
RT 550 Euro 5.0 cu ft 10.2 in 1500 rpm
4Hp 8/16/22 Hp
7.5 kW 10/15/20 kW
RT 850 Euro 15.0 cu ft 11.0 in 1500 rpm
10 Hp 13/20/27 Hp
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66. Introduction to Mass Finishing Massfin
6.3 Drying of finished parts – vibratory driers
Special application:
Drying of cutlery
Stainless steel vibratory
dryers with medium
CD Style 3000, 5000,
and 8500 models
RT – dryers with corn cob are
frequently used for drying of
cutlery coming from continuous
dishwashers.
Objective: Removal of water
stains and light polish!
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67. Introduction to Mass Finishing Massfin
6.3 Drying of finished parts – Hot air belt dryers
Hot air belt dryers BT Series
The wet parts are placed on a stainless steel mesh belt and
transported (variable speed) through a hot air drying tunnel.
BT systems are designed for continuous operation.
The BT – range consists of 4 models
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68. Introduction to Mass Finishing Massfin
6.3 Drying of finished parts – Hot air belt dryers
Hot air belt dryers
type BT
BT – dryers are mainly used for drying of mid-size to large, delicate
parts
with complex geometry, usually with openings like blind holes and
threads where drying media might lodge.
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69. Introduction to Mass Finishing Massfin
6.3 Drying of finished parts – Rotary drum type dryers
Rotary drum type dryers type TT
The parts are transported by way
of a rotating, perforated drum.
The drying process takes place
with drying media or hot air.
TT systems are designed
for continuous operation.
The TT – range consists
of models with a capacity
from of 1500 to 2500 lbs
parts per hour
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70. Introduction to Mass Finishing Massfin
6.3 Drying of finished parts – Rotary drum type dryers
Rotary drum type dryers
type TT
TT – dryers are mainly used for drying of small to mid-size parts
which might be
- cup-shaped (potential media carry-out)
and
- delicate (the TT movement is very gentle)
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6.4 Safety accessories and equipment
Mass finishing systems require certain
Protective accessories and equipment:
• Mass finishing is a very noisy process. The noise level
can easily reach close to 100 dB(A)
• Mass finishing equipment and the associated material
handling systems can consist of a multitude of moving
components
which can seriously harm people, if no protective
measures are taken!!
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6.4 Safety accessories and equipment – noise protection
Accoustic lids for circular
and tub vibrators
(noise reduction by about
10-15 dB(A))
Either manually or
pneumatically activated.
Accoustic lids allow
- easy access to the
finishing machine, and
- easy inspection of the
finishing process
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73. Introduction to Mass Finishing Massfin
6.4 Safety accessories and equipment – noise protection
Noise protection cabins
For the noise
protection of entire
Rosler finishing
systems
noise protection cabins
- with sliding doors
- lighting and
- ventilation systems
are available
Noise reduction down to 70 – 80 dB(A)!
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6.4 Safety accessories – against moving components
Protective cabin or fence
A fence protects the
operator and other
personnel
against any moving
components.
Any doors are guarded
with safety switches:
Doors can only be opened
when the finishing system
is switched off!
Noise protection cabins offer the same protection!
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75. Introduction to Mass Finishing Massfin
6.4 Safety accessories – against moving components
Safety mats
Occasionally electrically activated safety mats are
utilized for protection:
Any time a person steps on a mat surrounding the
mass finishing system,
the system turns itself automatically off!
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6.6 Quiz
1. How many types of mass finishing are there?
Please list all of them
2. What are the differences between
shot blasting and mass finishing?
3. Which products can be sold in the field of
mass finishing?
4. What types of mass finishing machines are
there?
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77. Introduction to Mass Finishing
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6.6 Quiz
5. What is the job of the grinding and polishing
media?
6. Which abrasive materials are used in grinding
media?
7. Which criteria determine media selection?
8. What is the function of compound?
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6.6 Quiz
9. What is the function of water in mass finishing?
10. Why are processing trials so important?
11. Mass finishing effluent contains which
materials?
12. Please list some types of
batch and
continuous machine
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6.6 Quiz
13. Which are the machine components of
drag finishing machines?
14. Which basic accessories are required
for any mass finishing machine?
15. Please list the material handling systems
which Massfin - Rosler offers
16. Please list the type of dryers Rosler offers.
What is the usable volume of the largest
BT-dryer?
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80. Introduction to Mass Finishing Massfin
6.6 Quiz
17. What is reverse screening?
18. Why must undersize media be removed
from a mass finishing machine?
19. Which types of noise protection does Rosler
offer?
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81. Introduction to Mass Finishing Massfin
The end
I hope you are
not going to do
the same with
me!
August 2010 Introduction Page 81