How to avoid excessive processing after shot blasting in Dalian

1、 Overview of Shot Blasting Processing in Dalian

Shot blasting is a surface treatment process that uses high-speed metal pellets (such as steel pellets, cast iron pellets, stainless steel pellets, etc.) to impact the surface of the workpiece, achieving the goals of cleaning, strengthening, and polishing. This process is widely used in fields such as automobile manufacturing, aerospace, mechanical manufacturing, and steel structure treatment. Shot blasting treatment can effectively remove surface defects such as oxide scale, rust, burrs, etc., while also improving the surface hardness and fatigue strength of the workpiece.

However, in actual production, there is also a risk of over treatment in shot blasting processing. Excessive shot blasting can lead to a decrease in the surface quality of the workpiece, damage to dimensional accuracy, and an increase in material loss, seriously affecting product quality and production efficiency. Therefore, how to avoid excessive shot blasting treatment has become a key issue in process control.

2、 The hazards of excessive shot blasting treatment

Surface quality deterioration: Excessive shot blasting can increase the surface roughness of the workpiece, resulting in the phenomenon of "over polishing" and defects such as pits and scratches on the surface.

Dimensional accuracy loss: Especially for thin-walled or precision parts, excessive shot blasting may lead to dimensional deviations, affecting assembly accuracy.

Material performance degradation: Excessive impact may cause microcracks on the surface, reducing the fatigue strength and corrosion resistance of the workpiece.

Increased production costs: Overtreatment not only wastes shot blasting media and energy, but also shortens equipment lifespan and increases maintenance costs.

Difficulty in subsequent processing: Overly shot blasted surfaces may not be conducive to subsequent processes such as painting and electroplating.

3、 Key control points to avoid excessive processing

1. Optimization of process parameters

Shot blasting intensity control: Select the appropriate shot blasting intensity based on the material and thickness of the workpiece. Usually, the Almen test piece method is used to determine the shot blasting strength to ensure that it is within the process requirements.

Shot blasting time control: Determine the optimal shot blasting time through experiments, establish a time surface quality relationship curve, and avoid unnecessary extension of processing time.

Projection angle adjustment: Reasonably set the shot blasting angle (usually 45 ° -90 °) to avoid repeated impacts in the same area.

Material selection: Select the appropriate material, shape, and particle size of the material according to the requirements of the workpiece. Generally speaking, pellets with high hardness and small particle size have stronger impact force and should be used with caution.

2. Equipment status monitoring

Shot blasting inspection: Regularly check the wear of the shot blasting blades, as severely worn blades can cause uneven ejection.

Pill screening system: Ensure the normal operation of the sorting system, timely remove broken pellets and dust, and maintain the flowability of the pellets.

Equipment maintenance: Conduct regular maintenance according to the manufacturer's requirements to ensure stable operation of the equipment.

3. Process quality control

First piece inspection system: Before processing each batch of workpieces, a trial throw is conducted to confirm that the process parameters are suitable before mass production.

Online monitoring system: Install online detection devices for surface roughness, coverage, etc. to monitor the processing effect in real time.

Regular sampling inspection: During the production process, regular sampling inspections are conducted to promptly adjust process parameters if any problems are found.

Complete process records: Detailed records of shot blasting parameters, equipment status, and other information for each batch of workpieces, facilitating traceability and analysis.

4. Personnel operation standards

Operation training: Provide systematic training to operators to enable them to understand process principles and key control points.

Standardized homework: Develop detailed operating procedures, standardize clamping methods, processing time, and other operational details.

Experience accumulation: Encourage operators to record their processing experience and form a better practical case library.

4、 Precautions for shot blasting treatment of special materials

Aluminum alloy workpieces: prone to over throwing, requiring lower strength and shorter time. It is recommended to use stainless steel or ceramic pellets.

Thin walled parts: Control the shot blasting intensity and use multi-point support clamping to avoid deformation.

Precision parts: It is recommended to use smaller pellets to reduce the impact energy of a single pellet.

Welding parts: Pay attention to the uniformity of shot blasting in the weld area to avoid excessive treatment of the weld.

To avoid excessive processing in shot blasting, systematic management is required from multiple aspects such as process parameters, equipment status, process control, and personnel operation. By establishing a scientific quality control system and implementing refined process management, the occurrence of excessive processing problems can be effectively prevented, while ensuring processing effectiveness and improving production efficiency and product quality. Enterprises should develop suitable shot blasting process specifications based on their own product characteristics, and continuously optimize and improve them to meet the increasingly high quality requirements.