Effective surface finishing of large, delicate work pieces
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 head-on with large vibratory systems from Rösler, which allow the cost effective processing of large, single components with absolutely repeatable finishing results.
One would have expected that surface finishing by hand disappeared from the industrial landscape a long time ago. But this is not so at all: 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 somewhat inconsistent surface finishes, it is also very expensive. Various manufacturers, especially those active in aerospace, are looking for ways to mechanize, and even automate, the finishing of such components. With its large tub vibrators Rösler offers a highly effective solution for the automatic finishing of large and heavy single work pieces. 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 utilizing tub vibrators for deburring and edge radiusing of structural fuselage components made from aluminum with lengths of up to 7,150 mm (282”). The processing tub with a width of 425 and a length of 7,400 mm (17 x 292”) is equipped with a powerful vibratory TUD drive. The drive system, directly connected to the processing tub, is evenly distributing the vibratory energy over the complete tub 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 tub 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 tub vibrator measuring 650 x 4,000 mm (26 x 158”) 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 work pieces at the same time, the processing tub can be partitioned into several chambers with special dividing plates. The work pieces are loaded into and removed from the tub with a crane.
A leading supplier of landing gears is also utilizing large vibratory systems from Rösler. These components are milled from a 2 m (79”) long titanium slab weighing 400 kg (880 pounds). 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 tub, measuring 800 x 3,000 mm (32 x 118”), with a crane. This particular tub vibrator is equipped with a so-called TSD direct drive. Two powerful vibratory motors mounted to the frontal walls of the tub generate a particularly intensive and even rotary movement of the processing media.
All three vibratory tub 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 tubs for quick loading and unloading of the work pieces.