Test Out Simulation of Shot Blasting Machines and Processes

In many industries shot blasting is used as a surface treatment technology. Rösler of Germany assists in this process by using simulation software along with virtual models that reduce the time for engineering, especially for large, complex machinery.

Shot blasting is a tool for surface cleaning, deburring, surface preparation for painting or coating and shot peening. As such the shot 
blasting technology is used for creating optimal surface finishes, to ensure problem-free downstream manufacturing operations or to optimize the 
functional characteristics of a product. Rösler supports its customers with simulation software during the planning phase for new shot blast equipment, especially regarding process development and optimization.

With the Rösler simulation software every physical stage of the shot blasting process, including the respective work pieces, can be displayed in a 3D model. This includes the blast media type, the thrown media quantity and the media flow. The data generated by the so-called particle simulation allow a precise evaluation of how much blast media is required, and with which impact energy it must hit different work piece surface areas to achieve 100%
coverage.

At the same time the data help determine the required turbine power, the ideal position of the turbines and the design of suitable work piece fixtures. The simulations facilitate the development of shot blast machinery and processes for achieving optimal shot blast results with the lowest possible number of turbines, low energy input and minimal machine wear. They also help reduce capital expenditures, operating costs and use of valuable resources.

Another benefit of simulations is that shot blast machinery for new workpieces can be planned on the basis of CAD data, well before the actual work pieces are available in prototype form. Simulations also provide insights as to whether the specified blast results can be achieved on work pieces with a given geometry. Should this not be possible, the simulation results provide valuable pointers regarding the optimization of the work piece
shape.

When shot blasting entire batches of relatively small work pieces, for example, in multitumbler blast machines (RMT), the optimal mixing of work pieces and blast media can influence the processing results and cycle times. For such applications, the software allows the simulation and optimization of the tumbling action of the work pieces in the drum-shaped blast chamber. This will result in the shortest possible process times. 

To reduce their energy consumption and wear rate and increase their operational efficiency, Rösler works with digital twins of the blast turbines. The replication of the particle flow provides a virtual analysis of the wear areas in a turbine. This, in turn, allows the implementation of geometrical turbine modifications for minimizing the wear rate.

Other simulations can be conducted with the goal of increasing the turbine efficiency, which, in turn, will result in energy savings. Thanks to the application of simulation software for the design of shot blast equipment and the respective processes, as well as for the optimization of the airflow and turbine technology, the lead times for Rösler shot blast machines are substantially shortened.

Sources: Press materials received from the company and additional information gleaned from the company’s website.