In many industries the surface treatment requirements are becoming more challenging. The demands include clearly defined quality specifications, short processing times, lower costs and resource-saving manufacturing processes. To meet these demands, among other tools, Rösler is utilizing simulation software for designing its shot blasting and mass finishing equipment and developing the best possible surface treatment processes. The software allows reducing the number of time-consuming and costly processing trials in the customer experience center. This helps to provide suitable equipment and processes to the customers in considerable shorter turnaround times.
Optimal shot blasting results within shorter cycle times, a lower media consumption and a more effective dust collection
The multiphysics approach of this ultra-modern simulation software allows the simulation and optimization of challenging shot blasting processes using 3D data. The simulation takes all process-relevant physical conditions into consideration. For example, the blast media can be thrown virtually on the respective work pieces, providing a portrayal of the actual shot blasting process. The realistic depiction of the various blast patterns and the media flow allows a reliable evaluation and adaptation of the effect of the media impact on the work pieces and the overall shot blasting performance. This results in more effective shot blasting operations with lower cycle times and costs. In addition, the optimized blast media flow reduces the wear rate in the blast chamber, which in turn minimizes equipment downtimes and brings about lower maintenance costs. The simulation also evaluates the dust load in the shot blast machine. Based on such evaluations the dust collection can be optimized for a safe and reliable handling of the generated dust. This helps prevent potential dust explosions in and around the machine. Of course, the simulation can also be used for equipment already operating in the field, irrespective of the original supplier.
Fast development of mass finishing processes for complex finishing tasks
So far, the development of finishing processes for work pieces with complex shapes, for example, knee implants, required lengthy and costly processing trials. For such applications the simulation software will not only help to achieve better finishing results but will also reduce the time for process development and save costs. The depiction of the motion of the grinding or polishing media in various shapes and sizes helps analyzing the effect of the media on the work pieces. This allows defining the ideal combination of media and equipment parameters. Moreover, the simulation of the media flow provides valuable data about the equipment wear.
Another significant benefit of these simulations is that it allows analyzing work pieces and finishing systems on the basis of existing CAD data. Processing trials with „dummy“ work pieces are no longer necessary.