Rösler has introduced groundbreaking advancements in the shot peening process, addressing the pressing needs for increased productivity, energy efficiency, and cost reduction in industries such as automotive and aerospace. Shot peening, the technique of hammering work pieces with precisely defined blast media, induces residual compressive stress, enhancing the durability of components like steering and transmission parts, springs, drive- and crankshafts, and turbine blades. Notably, this process allows for weight reduction without compromising mechanical load capabilities, a critical advantage for electric vehicles by extending their range and reducing energy consumption.
E-mobility’s evolving work piece structures and shapes necessitate frequent manufacturing process adjustments, with a strong emphasis on energy, resource, and cost efficiency. Rösler addresses these demands through innovative solutions, particularly the shift from energy-intensive compressed air blast systems to highly productive turbine technology. Turbine-based systems not only achieve precise shot peening results but also significantly lower energy consumption, eliminating the need for many costly compressed air systems.
Rösler’s optimization process begins with detailed computer simulations of the blast pattern and the entire process, followed by actual peening trials in their Customer Experience Center (CEC). The CEC is equipped with a wide range of turbine and compressed air blast systems, allowing trials under real production conditions. With an in-house X-ray diffractometer, Rösler quickly evaluates the trials to determine optimal process parameters and blast media.
A recent collaboration with a leading European automobile manufacturer exemplifies the benefits of Rösler’s approach. The project resulted in a 30% reduction in energy consumption and a 50% increase in shot blast capacity. These impressive results led to the purchase of four turbine-equipped shot peening machines by the manufacturer.
To further enhance productivity, Rösler emphasizes the importance of reviewing and optimizing existing shot blasting parameters. This review can identify opportunities for process improvement, reduce equipment wear, and lower operational costs. When necessary, retrofitting machines with more powerful turbines or developing new work piece fixtures can be the right solution. Optimization always includes thorough shot peening trials and evaluations to ensure compliance with peening specifications.
The selection of the right blast media is crucial for resource and cost efficiency. Rösler conducts comprehensive blast media analyses to determine the best fit for specific applications. Depending on the requirements, shot peening can be performed as a wet or dry process, each with distinct advantages. Dry peening offers higher blast intensity and precise targeting of surface areas, while wet peening prevents media embedding and produces lower surface roughness, ideal for delicate work pieces.
Rösler’s extensive range of machine types ensures an objective equipment selection, providing customers with the best possible solution for their needs. The company’s flexible process alteration and optimization capabilities guarantee consistent, high-quality peening results throughout the equipment’s lifespan, meeting all demands for energy, resource, and cost efficiency.
