How to control the stability of shot blasting parameters in Dalian?

Dalian shot blasting processing, as an efficient and environmentally friendly surface treatment technology, plays an important role in modern manufacturing. With the continuous advancement of technology, shot blasting processing will be applied in more fields and provide strong support for the green and intelligent development of industrial production. However, in the face of challenges from new materials and processes, shot blasting technology still needs continuous innovation and improvement to meet the higher demands of future manufacturing industries.

Shot blasting is a surface treatment technology that uses high-speed projectiles (such as steel balls, steel grit, ceramic balls, etc.) to impact the surface of the workpiece in order to achieve cleaning, strengthening, deburring, and improving surface roughness. The basic principle is to use a shot blasting machine to accelerate the projectile to a certain speed and uniformly project it onto the surface of the workpiece. Through the impact of the projectile, impurities such as oxide skin, rust, and welding slag on the surface are removed, and a certain amount of compressive stress is generated on the surface of the workpiece to improve its fatigue strength and corrosion resistance.

How to control the stability of shot blasting parameters in Dalian?

Equipment selection and maintenance

Choosing high-quality equipment: Shot blasting equipment with advanced control systems and stable mechanical structures is the foundation for ensuring parameter stability. For example, using a well-known brand with a good reputation for shot blasting machines, their manufacturing process and quality control are relatively strict, which can provide hardware support for stable parameters.

Regular maintenance: Develop a detailed equipment maintenance plan, regularly inspect various components of the shot blasting machine, such as the impeller, blades, and dividing wheel of the shot blasting machine, and replace them in a timely manner if wear is found. At the same time, inspect and maintain the electrical and control systems of the equipment to ensure their normal operation and avoid parameter fluctuations caused by equipment failures.

Accurate debugging of equipment: Accurate debugging must be carried out after equipment installation and each maintenance. Including adjusting the angle and position of the shot blasting device to ensure that the shot can be evenly ejected onto the surface of the workpiece; Calibrate the control system for shot blasting speed and shot blasting volume to accurately operate according to the set parameters.

Management of projectiles

Control projectile quality: Choose projectiles with stable quality, uniform hardness, and regular shape. Regularly test the hardness, diameter, and other parameters of the projectile to ensure that it meets the process requirements. For example, for cast steel shot, its hardness should be within the specified range, and the diameter deviation should not be too large to ensure the consistency of shot blasting effect.

Keep the projectile clean: During use, the projectile may adsorb impurities such as dust and oil, which can affect its performance. Therefore, it is necessary to equip effective projectile cleaning and separation equipment, regularly clean and screen the projectiles, remove impurities and broken projectiles, and ensure the cleanliness and integrity of the projectiles.

Reasonably replenish pellets: As shot blasting progresses, pellets will continuously wear and consume, and new pellets need to be replenished in a timely manner. The frequency and quantity of supplementing bullets should be reasonably controlled according to the actual production situation. It is generally recommended to supplement appropriately when the consumption of bullets reaches a certain proportion (such as 30% -50%) to maintain the stability of shot blasting volume.

Monitoring and adjustment of process parameters

Installation of monitoring equipment: Install relevant monitoring equipment at the shot blasting processing site, such as speed sensors, shot blasting volume monitors, surface roughness detectors, etc. Real time monitoring of key parameters such as shot blasting speed, shot blasting volume, and workpiece surface roughness through these devices, and feedback of data to operators or control systems.

Establish parameter standards: Develop detailed shot blasting processing parameter standards based on the material, shape, size, and processing requirements of the workpiece. Clearly define the reasonable range and tolerance requirements for each parameter, such as controlling the tolerance of shot blasting speed within ± 5m/s and shot blasting volume within ± 10%. Operators strictly follow the standards for operation and monitoring during the production process.

Timely adjustment of parameters: Adjust shot blasting parameters in a timely manner based on the data feedback from monitoring equipment and the actual processing situation of the workpiece. If the surface roughness of the workpiece does not meet the requirements, optimization can be achieved by adjusting the shot blasting speed, diameter, or time; If there is a fluctuation in shot blasting volume, the working status of the shot conveying system and shot blasting machine should be checked, and faults should be promptly eliminated and adjusted to the appropriate shot blasting volume.

Training and management of operators

Professional skills training: Provide systematic training to operators to familiarize them with the working principles, operating methods, and parameter adjustment skills of shot blasting equipment. The training content includes equipment operating procedures, safety precautions, common troubleshooting methods, etc., to ensure that operators can operate the equipment correctly and ensure the stability of processing parameters.

Operation standard management: Establish strict operation standards and workflow, requiring operators to strictly follow the standards during the production process. For example, before starting the device, a comprehensive inspection of the device should be conducted; During the processing, it is important to closely monitor the operating status and parameter changes of the equipment, and promptly record relevant data; After the equipment is shut down, it should be cleaned and maintained. By standardizing operational procedures, we can reduce parameter fluctuations caused by human factors.

Shot blasting processing can not only clean the surface, but also improve the mechanical properties of the workpiece through shot blasting strengthening technology. Shot peening is the use of high-speed abrasives to impact the surface of a workpiece, causing it to generate compressive stress, thereby improving the fatigue strength, stress corrosion resistance, and wear resistance of the workpiece. This process is widely used in aerospace, automotive manufacturing, mechanical manufacturing and other fields, especially for the treatment of high-strength alloy steel, aluminum alloy and other materials.

Bullets are key materials in shot blasting processing, and their material, shape, size, and hardness all affect the processing effect. Commonly used pellets include steel shot, steel grit, ceramic shot, etc. Steel shot and steel sand are mainly used for cleaning and strengthening metal workpieces, while ceramic shot is used for workpieces with high surface requirements, such as precision parts, electronic components, etc.