Leading Company World Wide in the field of Vibratory/Mass Finishing

1. INTRODUCTION TO MASS FINISHING ROSLER Leading Company World Wide in the field of Vibratory/Mass Finishing

2. What is mass finishing? Mother nature prove to us how the odd shaped stones and rocks are transformed into round stones and pebbles. It happened with help of the one constant motion and two ingredients – Grinding with water and sand.Rosler media transformed this process into controlled sophisticated process/operation

3. The elements of the mass finishing Water Finished part Raw part Compound and media Effluent

4. The mass finishing process In the work bowl of a vibratory finishing machine, the media, work pieces/parts, compound and water are put into motion. This is causing a relative movement between media and work pieces/parts. This movement create grinding of media against the surfaces and edges which produce removal of material.

5. Types of mass finishing processes Deburring Radiusing Polishing Rosler has been developing this processes into all-round highly productive technology of surface finishing. Smoothing Cleaning Degreasing Descaling Ball polishing

6. Application of the process: Mass finishing or Shot blasting

7. Equipment ,Consumables and Parts for sale in Mass finishing industry Spares; Polyurethane relines Finishing equipment Finishing compounds Ceramic and Plastic media Flocculation compounds Peripheral equipment Process waste water and Effluent treatment - centrifuges

8. 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 the parts and grinding/polishing media. The elements of mass finishing machinery The mass finishing machinery

9. Types of mass finishing machinery Round Vibratory Machines Vibratory Tubs Drag Finishing Machines Centrifugal Disk Machines

10. Grinding and Polishing media The media – either for grinding or polishing does the actual work by constantly rubbing against the parts Elements of mass finishing - media Plastic media Ceramic media

11. About media All media wear during the mass finishing process

12. Types of media Corn cob drying and polishing granulate Anti adhesion balls Plastic media Porcelain polishing media Steel media Ceramic media Glass beads

13. Media selection Questions that end user need to know prior process is established: Desired grinding effect? Desired rate of wear? Is chipping of the media problem? Desired surface smoothness? Danger of media logging into parts? Grinding of inner parts contours required? How can parts and media be separated?

14. Compounds Compounds are required to support the mass finishing process

15. Compounds job To dissolve dirt and grease from the parts surfaces To clean the media tokeep their grip To remove media and metal fines and dirt from the machine To protect the finished parts against corrosion and oxidization

16. Types of compounds Rosler compounds clean the effluent coming from the mass finishing process by separating solids and oil from the liquid. Rosler Pastes for polishing Liquids Powders Effluent going to drain For recycling in centrifuges For shock degreasing and for grinding support

17. The elements of mass finishing - water Almost allmass finishing processes are wet. Process water does: Dissolve and distribute compound Act as a coolant in vibratory process Removes metal fines and media Absorbs dust

18. Relation of the components in process Water Good process is established only if: Type of the machine Shape, size and type of media Kind and amount of media Media Compounds Effluent ARE WELL CHOSEN !!! Optimal finishing results can be achieved.

19. Importance of test trials Customer surface finishing problem Mass Finishing is an empirical Technology. It is based on test trials. With most projects, a successful sale is preceded by a successful trial. Precise definition of finishing task Processing test trial Trial successful? High probability of getting the order NO YES

20. Effluent (waste process water) treatment

21. Major waste process water cleaning systems Flocculation is needed if effluent is to be discharged to drain. Centrifuges are used if effluent is to be recycled.

24. high water/compound consumption

25. high operating cost

27. Semi-Automatic Centrifuge Rosler centrifugal force technology removes solid fines from the process water by applying centrifugal force up to 2400 times greater than the Earth's gravitational pull (1 g). The cleaned process water is recycled back to the mass finishing machine(s), saving up to 98% in water costs. Since the compound in the cleaned process water remains active, this can yield savings of up to 90% in compound costs.

28. Automatic Centrifuge Z 1000 ASS-II peeling centrifuge with fully automatic operation The PLC-controlled, fully-automatic Z 1000 cleans 500 gallons of effluent per hour with ease. The sludge deposited on the drum wall is automatically removed with a peeling knife and discharged into a sludge container.

29. Mass Finishing Machinery Powerful Robust

30. Types of Mass Finishing Machinery There are two types of classifying Mass Finishing equipment: 1. Type of relative movement between parts and media 2. Type of parts processing (batch or continuous)

31. Process of relative movement between parts and media 1. Vibrators - Circular vibrators - Trough or tub vibrators 2. Centrifugal Disk Finishing machines 3. Drag Finishers

33. vibratory drive (flange motor)

35. rectangular work bowl

36. vibratory drive (either foot motor or electr. motor with imbalance units) applications using stainless steel, ceramic or plastic media TS series tub vibrators, with processing bowl widths up to 1,100 mm and lengths up to 3,000 mm. Delicate, large components can be finished in a gentle fashion in long straight tubs. For efficient noise reduction, we offer noise absorbing covers or complete noise absorbing cabins.

37. Centrifugal Disk Finishing Machine – principal of work The high performancecentrifugal diskmachines containa rotating disk (spinner)as the bottom of acylindrical workbowl

38. Centrifugal Disk Finishing Machine FKS Tandem systems to meet high production requirements. Features: Processing unit includes integrated: hydraulic loader intermediate vibratory hopper screening machine media return conveyor spinner and work bowl lined with wear-resistant hot-pour polyurethane specially-designed spinner and bowl geometry provide up to 5000 hours of spinner/bowl life special features including: automatic gap control and adjustment high water level processing wrap-around screens for small parts magnetic separation and many more Automatic disc finishing system with the Rösler 2--Batch-System® with magnetic separation.

42. Batch System

43. Continuous System

44. Continuous Systems Typical continuous systemsare continuous vibrators

45. Accessories Rosler Surface Finishing Machines must be equippedwith certain basic accessories: Electrical controls Compound and water dosing systems Effluent collecting and pump stations

46. 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.

47. 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 shootingMassfinelectrical engineerscan directly access the customer‘s control panelvia modem. This helps to minimizedowntimes!

48. Accessories – Dosing System 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

50. float switches

53. drying of the processed parts

54. safety, like noise protection

58. Conveyor belt systems Example of conveyor belt systems

59. Rosler Conveyors and handling system

60. Separation Systems – Integrated Separation Systems 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! Almost all roundvibrators have an integrated separation system.

62. the media and parts have a similar size aMagnetic Separator can be the solution to such a problem! Precondition formagnetic separation: Parts must be ferrous!!!

64. Rotary drum type dryers - with drying media - with hot air

65. Vibratory Dryers 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

66. Vibratory Dryers 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

67. 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

68. 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.

69. Rotary Drum 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 designedfor continuous operation. The TT – range consists of models with a capacity from of 1500 to 2500 lbs parts per hour

70. 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)

71. 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!

72. 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!!!

75. lighting and

76. ventilation systemsare available Noise reduction down to 70 – 80 dB(A)!

77. 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!

78. 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. What types of mass finishing machines are there? 4. What is the job of the grinding and polishing media?

79. Quiz 5. Which abrasive materials are used in grinding media? 6. Which criteria determine media selection? 7. What is the function of compound? 8. What is the function of water in mass finishing?

80. Quiz 9. Why are processing trials so important? 10. Mass finishing effluent contains which materials? 11. Please list some types of batch and continuous machine 12. Which are the machine components of drag finishing machines?

81. Quiz 13. Which basic accessories are required for any mass finishing machine? 14. Please list the material handling systems which Massfin - Rosler offers 15. Please list the type of dryers Rosler offers. 16. What is the usable volume of the largest BT-dryer?

82. Quiz 17. Why must undersize media be removed from a mass finishing machine? 18. Which types of noise protection does Rosler offer?

83. THE END Here at Massfin, we hope that this pps. was of a value to you. Best Regards, Massfin