Centrifugal Disc Finishing

Transcription

1 Surface Finishing Applications we redefine Centrifugal Disc Finishing

2 Mass Finishing Centrifugal Disc Finishing Applications Deburring Degreasing & Oil Removal Cleaning Descaling Radiusing Smoothing Polishing ActoGrind 2 3

3 Technical Information Semi-automated Centrifugal Disc Finishing Machine Control System To suit functionality of the machine, suitable control systems are used. These control systems could be either operated via a push button system or via a touch screen using PLC control systems. The standard machines come with a standard control panel with variable speed and process time controls. Through the PLC settings such as disc RPM, temperature adjustment or gap area setting can be controlled. Unloading System Components and consumables are 100% discharged at the end of the finishing process through the tilting of the working barrel. Separation System Includes a large separation screen and has its independent drive system. Upon completion of the process, parts and media are fed into the vibratory separation system and are separated via the screen. If components are flat, water jets can be connected to ensure all parts are discharged. The separation screens are made out of polypropylene and the sizes of holes and slots can be manufactured depending on the geometry of the part being processed and the type of media used. An undersized media separation system can also be incorporated. Work Chamber Temperature Sensor Dosing System The system is capable of handling all types of ActOn s liquid compounds to the disc finishing machines giving a clean component, extended media life and also keeps the work bowl of the machine clean. To comply with local Water Authority regulations the liquid compound and water are dosed separately to the equipment via a dual feed system, eliminating the need to fit expensive header tank. Gap Area Specially designed gap area between the disc and the working barrel, for particular finishing applications. The geometry of the gap area is crucial for an improved life of the disc finishing machine. Gap Area Adjustment During the finishing process the width of the gap area can be adjusted manually on the standard series. Optional automatic adjustment through the disc finishing machine controls available for certain models. To stop the disc finishing machine when detecting high temperature thus protecting the gap area. Polyurethane lined work barrel to ensure fabrication is protected and components are processed in an effective manner. ActOn has its special grade polyurethane materials formulated, which enhance the overall life of the centrifugal disc machine. Wedge lining available to ensure parts do not get stuck to the side walls. The process chamber is stress relieved to improve life. 4 Stainless steel upper and lower ring for higher wear resistance. 5

4 Centrifugal Disc Finishing Machine ActOn s Centrifugal Disc finishing machines have been designed to be reliable and easy to operate. Technical Information The Centrifugal Disc machine is perfect for processing small and thin components as well as larger parts with a length of 150mm. These machines are recommended for processing small to medium batches of parts. One of the main advantages of Centrifugal Disc machines is the reduced processing times for most applications. How it works? The spinning motion of the disc machine is given by the disc situated at the bottom of an open barrel. The rotating disc makes the media, compound and parts to move in a rolling motion, resulting in effective finishing process in the shortest time. To achieve the desired finishing results it is important to set up the machine RPM, the compound and water mix flow and to use the correct media. Key Benefits Efficient in operation. Faster than vibratory finishing machines. Operator friendly controls. Low maintenance. Manual/ auto functionality. Good value for money as it implies a reduced capital investment. DTB series for heavy duty applications such as steel ball burnishing. For fully automated solutions, such as coin blank finishing systems, we recommend our CHE-DT series. Contact us for more information. 6 7

5 Accessories and Extras Centrifugal Disc Finishing Range The above accessories are the most commonly used. Please refer to our accessories brochure for more options along with detailed description. Standard Optional 8 9

6 Case Study Automation CHE-DT Disc Finishing System for Coin Blanks Description This ActOn Disc Finishing system is unique in design and meets the highest standards required by the mint industry. The design allows continuous output: while the finished batch of coin blanks are separated from media and discharged, a new batch is being processed in the disc finishing machine. The process is fully automated and controlled from the point of coin blanks being processed to the discharge of the parts. Advantages Temperature Sensor To stop the disc finishing machine when detecting high temperature thus protecting the gap area. Gap Area Work Chamber Polyurethane lined barrel to ensure fabrication is protected and components are processed in an effective manner. Stress relieved work chamber to improve life. Disc can be adjusted manually or automatically Powerful heavy duty speed drive. Result: coin blanks finished to a high specification without any contamination of dust or presence of surface defects. A fully automated system designed and manufactured to ensure process control and repeatability. Full control of process with minimum reliance on operator. Suited to small and large volumes of parts. Savings in operating cost PLC and HMI Controls all equipment and process in the system from start to finish. Alpha-numeric part number specific recipes can be programmed. Maintenance schedules with alarms programmed for preventative maintenance. All password protected. Dosing System The system is capable of handling all types of ActOn s liquid compounds to the disc finishing machines giving a clean component, extended media life and also keeps the work barrel clean. Linear Drier The drier design includes a hot air blower which distributes the heat via a textile tube through nozzles. After being separated from media, the coin blanks are discharged into the drier and gently carried through the tube. The finished coin blanks are dust and damage free. Alternatively, maize and hot air dryers can be used. Media Return System This has been integrated to carry the media from the storage hopper into the finishing machine. The main advantage of the conveyor is that it reduces the manual handling, hence reducing the time spent to load the machine. Specially designed gap area between the disc and the working barrel, for particular finishing applications. The geometry of the gap area is crucial for an improved life of the disc finishing machine. Gap Area Adjustment During the finishing process the width of the gap area can be adjusted automatically through the disc finishing machine controls. Storage Hopper Used as an intermediate storage hopper and feeder for controlled feed to separation system. Incorporates a drain for discharge of residual effluent. Separation System Includes a large separation screen and has its independent drive system. Due to the flat geometry of the coins water jets are connected to ensure all parts are discharged. The separation screens are made out of polypropylene and the sizes of holes and slots are manufactured depending on the geometry of the part being processed and the type of media used. Includes an undersized media separation system

7 Products we manufacture Bowls Each of our Bowls are simple to operate, highly efficient, and manufactured in classic designs and sizes to meet your unique applications. Centrifugal High Energy Engineered with the latest technology, the drive mechanism is designed to produce high g-forces, resulting in shorter process times. This technology can be used for both wet and dry processes. Troughs We offer Troughs in many different sizes and an infinite choice of length and width combinations, making them one of our most versatile. These are particularly useful for larger components. Centrifugal Disc Finishing Centrifugal Disc finishing machines have been designed to be reliable and easy to operate. The spinning motion of the disc machine is given by the disc situated at the bottom of an open barrel. The rotating disc makes the media, compound and parts to move in a rolling motion, resulting in effective finishing process in the shortest time. Duals The orbital Dual finisher works to both deburr and dry in one single unit. This is both an excellent and economical finishing option. Waste Water Treatment During the finishing operation, the effluent can be polluted with oil, media and metal fines. Our customers trust us to help select a waste water treatment system that complies with the industry s growing regulations. Once processed, the effluent is treated in the ActOn centrifuge system before being discharged to the drain or recycled. Dryers Our unique, elliptical-shaped Vibratory bowl drying machines are compact in size, and simple to operate. The design provides the flexibility to use it as an effective 1 lap drying process or a multi lap process. We also offer centrifugal dryers, conveyorised ovens and rotary dryers. Automation Both the Vibrota and High Energy can be automised to reduce manual handling, and to ensure a consistent process. Our automated systems are operator friendly, and can be custom built to suit your needs. 12 Wheel Polisher Suitable for achieving a highly polished finish on wheels with different sizes (up to 610 mm), the AWP188 machine has been designed to be simple to operate and to produce excellent results. The wheel polisher is great for grinding, smoothing and polishing processes. Consumables Our consumables are an important aspect of finishing. From ceramic, plastic, drying and blasting media to liquid compounds, we ensure that you achieve the optimum results in the most cost-effective way. Please refer to our individual product brochures for more information. 13

8 Consumables Consumables Over the years, we have been at the forefront of the industry, developing a range of consumables with the aim of achieving the desired finish on various components. By working closely with highly skilled manufacturers, our Engineers understand the numerous challenges faced in different industries, which has led to the development of suitable consumables. Choosing the right consumables is crucial in achieving your desired finish, and we endeavor to help you, and all customers, select the media and compounds right for your products. Please refer to our consumables brochure for more information. Liquid Compounds Compounds are very important to the mass finishing process. An extensive range of specially formulated compounds is manufactured on site, which suit almost any application. Compounds accomplish cleaning, inhibiting for rust and corrosion of parts, brightening, descaling and degreasing. Often, the compound reduces media costs and reduces process time. All of our compounds are biodegradable, too. Plastic Media Our range of plastic media comes in various grades, shapes and sizes and is specially designed for smoothing processes and removing light burrs. This media also reduces the risk of part damage, and gives us a consistent, bright and matte finish. Powder & Pastes A full range of powders and pastes are available, all of which complement the media and contribute to the grinding, cleaning and polishing of ferrous and non-ferrous materials. These products are suitable in freshwater operations. Ceramic Media Our ceramic media comes in a variety of abrasive grades, starting from low abrasive to super finishing. This type of media is suitable for various deburring, radiusing and polishing processes, and is specially formulated to go hand-in-hand with ActOn s compounds. Agro Media Part of our agro media range is corncob and walnut shell. Both products come in various grain sizes, which are carefully chosen to suit the specific parts. The corncob grains are known to have high abrasion resistance, good moisture absorption, low specific gravity and are employed mainly for drying in the Rotary Dryers and Vibratory Dryers. Walnut shell is a hard and fibrous material of medium abrasiveness, and is used in both the polishing and deburring processes as it leaves no scratches or pitting. Pre-treated Media All of our agro media comes in a treated, bovine-free form, which is particularly suitable for high lustre or mirror finishes. Special Media Our special media includes steel media; a separation ball media that keeps flat parts separate, ensuring they don t stick together

9 Additional Services Value Added Service On top of our state-of-the-art machinery and media, we also supply a range of support and training services. Learn more on how you ll benefit: Waste Water Treatment During the finishing operation, the effluent can be polluted with oil, media and metal fines. It is critical that the effluent must be treated before going to drain, or if it is being recycled back into the system. Each area or district has its own discharge consent, hence the effluent must be analysed against this. The effluent can be recycled, however there are certain applications where it is not possible. In those cases, the treated effluent can be transferred directly to the drain. Recycling can save on the significant amount of water and compounds (greater than 90%) used. We offer a range of flocculants (powder and liquid) coupled with our Centrifugal technology. Please refer to our waste water treatment brochure for more details. Subcontract Services Precision Polishing In order to provide you with complete surface finishing solutions, we offer a precision polishing service for components from various industry sectors. In combination with our barreling capability, you ll benefit in terms of cost, delivery and quality. Our applications include removal of manufacturing defects on femurs and aerofoils, which are inherent in the casting and forging process. Inspection High Energy and Vibratory Finishing Services Our factory is well equipped with High Energy (HE) and Vibratory machines, which are designed and manufactured by our Engineers. The HE machines provide a speedy finishing solution, as well as a high quality finish to the parts, eliminating any need of fixturing and preventing their impingement. Along with the HE machines we also have Vibrota finishing equipment, which processes parts of variable sizes and batch quantities. Shot Blasting and Peening Services Our trained inspectors ensure every component is inspected to the required specification prior to delivery. The inspections can include visual, dimensional and surface finish measurements. Our document controls ensure that all inspections are recorded for traceability purposes. We offer a comprehensive blasting service from our Stourbridge facility to our customers from different industries. Our service can achieve the desired Sa standards to ensure that the part s surface is cleaned to the specification. This ensures the metal is prepared for the coating stage avoiding any future failures. After-sales, Training and Installation We hire a number of highly trained staff, including engineers, who are on-call for all of your after-sales requirements. From installation and training, to maintenance and prompt professional advice, our finishing specialists are here for you every step of the way

10 Quality you can see What Our Customers Say Switching from manual finishing parts to disc finishing was a step ahead for improving operation efficiency in our business. Quality You Can See We pride ourselves on our excellence, and over the years we have successfully demonstrated an ongoing compliance with ISO quality and environmental standards. For ISO, we currently hold: We work with ActOn team to constantly improve our finishing processes. Over the years they have proved to be an essential partner for us. We re proud members of the Made in Britain campaign

11 we redefine ActOn Finishing Limited 213 Torrington Avenue Tile Hill, Coventry, CV4 9HN. United Kingdom. +44 (0) ACT-36-CDF Issue 01