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Gently does it
Tuesday, 26 June 2018 00:00

Rosler has demonstrated effective surface finishing of large, delicate components in large vibratory systems

The deburring, edge radiusing and polishing of large, long, heavy and, at the same time, delicate components, usually poses a considerable technical challenge. This challenge can be met with large vibratory systems from Rösler, which allows the cost-effective processing of large, single components with absolutely repeatable finishing results.

Surface finishing by hand, manual deburring and surface smoothing is still the prevailing method for finishing the surface of very large, heavy and delicate components. Apart from the fact that such manual work produces inconsistent surface finishes, it is also very expensive. Various manufacturers, especially those active in aerospace, are looking for ways to mechanise, and even automate, the finishing of such components. With its large trough vibrators Rösler offers a highly effective solution for the automatic finishing of large and heavy single components. These machines are equipped with custom-engineered vibratory drive systems developed and built in-house. Depending on the finishing process, their speed can be varied between 1,500 and 3,000 RPM. Automatic process water cleaning and recycling systems ensure that the vibratory process produces absolutely consistent and repeatable finishing results 

 

Many aerospace applications

For example, a leading aircraft manufacturer is utilising trough vibrators for deburring and edge radiusing of structural fuselage components made from aluminium with lengths of up to 7,150 mm. The processing trough with a width of 425 and a length of 7,400 mm is equipped with a powerful vibratory TUD drive. The drive system, directly connected to the processing trough is evenly distributing the vibratory energy over the complete trough length with multiple imbalance units. This guarantees a highly intensive media/work piece movement at very short cycle times. Within certain time intervals the processing media is removed from the trough and passed through a vibratory undersize media classification system before being returned. This ensures a stable media operating mix.

At another aircraft manufacturer various sizes of complex, structural components are finished in a Rösler trough vibrator measuring 650 x 4,000 mm after CNC machining. Besides deburring and edge radiusing, these components which to date were finished manually, also require a homogeneous surface finish. In order to process assorted smaller components at the same time, the processing trough can be partitioned into several chambers with special dividing plates. The components are loaded into and removed from the trough with a crane.

A leading supplier of landing gears is also utilising large vibratory systems from Rösler. These components are milled from a 2m long titanium slab weighing 400 kg. After the milling stage burrs must be removed, the edges radiused and the milling grooves smoothed out to prevent a potential notching effect. The milled component is lifted into the processing trough, measuring 800 x 3,000 mm with a crane. This particular trough vibrator is equipped with a TSD direct drive. Two powerful vibratory motors mounted to the frontal walls of the trough generate a particularly intensive and constant rotary movement of the processing media.

All three vibratory trough systems are equipped with custom engineered noise suppressing enclosures. Their design ensures not only a significant reduction of the operating noise but also easy access to the troughs for quick loading and unloading of the components.

 
 

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