When Should You Consider Recycling Vibratory Waste Water?

Posted on February 22, 2012 by Precision Finishing Inc.

 If you are paying for your water and you are operating a large or multiple vibratory pieces of equipment, your water bill could be substantial. Recycling your waste water could significantly reduce your cost of operation.   Also, if you are looking to add Green technology to your manufacturing operations, recycling your vibratory waste COULD be an easy way to GO GREEN!   Not only could you save water, proper filtering can enable you to reduce your usage of vibratory chemistry.

However, you must understand that recycling isn’t as easy as it sounds and             isn’t suitable for all vibratory processes.

If your vibratory process entails the use of two or more compounds and you recycle this water it is impossible to control the quality and final finish of your parts. If however you are using a single compound in your process, your recycled water is more easily controlled resulting in a consistent finish.

The vibratory process is inherently dirty and if it isn’t filtered you will redeposit this dirt onto your parts during processing.  If your recycled waste isn’t filtered properly or filtered at all before returning to the vibratory process, you may cause serious issues such as:

  • Oxidation / Rusting
  • Smutty or dirty surfaces
  • Problems for final coatings or finishes
  • Longer time cycles

Proper recycling of vibratory waste water should entail the removal of the ultra fine particles from the waste stream and leave most of the chemistry behind.  Using one compound enables you to control your process by adding the proper amount of chemistry to your filtered water in order to maintain a consistent finish.   Close monitoring is also required of your recycled water because of salt build up in your water.  Uncontrolled levels of salt can also create serious issues you your final finish.

Recycling of you vibratory waste water can be very advantageous and cost effective if done properly.  Precision Finishing will take the time to truly understand your process and has the experience to determine whether recycling is applicable for you.     

Jeff Bell
Precision Finishing Inc.

Posted in Recycling Vibratory Waste Water, Vibratory Waste | Leave a comment

Why Use An Evaporator For Vibratory Waste

Posted on February 22, 2012 by Precision Finishing Inc.

 The use of evaporators can be a very easy and simple solution to meet a zero discharge requirement.  Whether you want to evaporate straight vibratory fluid out of your machine or evaporate a concentrated solution generated from some type of filtering system, evaporation can be a consideration.  

 

Companies generating 50 – 100 gallons per day of fluid can utilize what they call a drum evaporator which evaporates between 200-400 gallons per week or 1.5 – 3.0 gallons per hour or tap water. The more solids in your waste stream the lower the evaporation rate.   Additionally drum evaporators are convenient for removing water from a 10 -20 % solid vibratory waste content.

Jeff Bell
Precision Finishing Inc.

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Shot Peening

Posted on October 15, 2011 by Precision Finishing Inc.

When metal is machined or formed you actually change the molecular structure of the material. Altering the metal surface actually creates tensile stresses across the surface of the material which increases the chances of fatigue cracking. By applying a residual compressive stress to the surface you remove or reduce the tensile stress created which reduces fatigue cracking and thus increases the fatigue life of the part.

                                            So you say Big Deal! 

The amazing part about shot peening is you can actually increase the fatigue life of a part by  200% – 300%!  That is huge when you are talking about extending the life of a part before it fails, especially when the part operates in a high stress environment.  The major advantage of shot peening is to increase the fatigue life of the part but is also used to  improve the durability of certain coatings.

At Precision Finishing we shot peen utilizing conventional air blast and wheel blast equipment. Shot peeing is a very critical and certified process and is successful only when all of the parameters are considered. Some such considerations are:

  • Part Material, hardness and thickness
  • What areas should be shot peened
  • What areas definitely should not be shot peened
  • Media type and hardness
  • Intensity required
  • Equipment Type
  • Velocity

Because you are drastically changing the surface of the part, shot peening can easily destroy a perfectly good part if it isn’t done correctly.  It is imperative that you work with an organization which has a complete understanding of the process to assist you in incorporating the shot peening process.  Our Precision Finishing contract shop is ISO certified and we shot peen to military specifications to assure that your part is done correctly.  Offering shot peening services has also enabled us to develop the expertise to assist in equipment / process recommendation and training to customers wanting to perform this process in their own facility.   

Jeff Bell
Precision Finishing Inc.

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Spray vs. Dunk Tank Washing

Posted on August 29, 2011 by Precision Finishing Inc.

Cleaning parts to meet specifications is a critical step in the production process. There are well established methods – Spray washing and Immersion-Agitation Cleaning (also known as Dunk Tank Washing). The key question in cleaning is “what’s the best method of getting the solution to all surface areas that need must be cleaned?” Answering this question helps determine whether immersion-agitation or spray is most appropriate.

Immersion-agitation is very effective with complex geometries with open access to external and internal surfaces. For example a part with internal thru-ports (as opposed to blind holes) and threaded areas is a prime candidate for dunking.

The advantage of Immersion-Agitation over Spray:
Immersion effectively handles a wide range of chemistries — both aqueous based and volatile or solvent based. Immersion-Agitation utilizes a platform to hold either individual parts or a basket of parts. The platform submerges into the cleaning fluid and begins an up-and-down movement which introduces a mechanical scrubbing action to move debris and contaminants off the parts. The flow of the fluid flushes any loosened debris away from the parts surface.
Today’s immersion cleaning processes can be quite sophisticated, adding basket rotation or ultrasonic action to individual stages.

The advantage of Spray over Immersion:
In spray washing multiple operations (wash, rinse, dry) can be completed in a single, small cabinet saving substantial floor space. A basket holds the parts and rotates while spray nozzles directed from top, bottom and sides contact all exposed areas of the parts. In cabinets there are two available cleaning styles — flood washing which uses a high volume of fluid at a low pressure and impact washing which uses low volumes of fluid at high pressure. Spray washing is most effective on single layers of parts.

Spray Cabinet Washer

Cleaning is so advanced now. Choice of equipment, chemistry selection, parts configuration, material handling, available floor space and desired cleaning results are all factors to consider. The process can seem overwhelming. Eliciting help from a knowledgeable distributor and their partner manufacturers is an excellent course of action. Both are highly motivated to define the process goals and design & develop the proper system to make the cleaning process user friendly and deliver reliable, repeatable results.

Judy Sheasley
Checker Industries

Posted in Dunk Tank Washing, Immersion washing, Spray Washer | Leave a comment

Vibratory Compounds

Posted on July 29, 2011 by Precision Finishing Inc.

Our line of Chemtrol vibratory compounds has grown with the finishing industry since 1955 and we continue to specialize in the formulation and manufacturing of compounds for use in the vibratory finishing process.

The vibratory finishing process has multiple variables of which compounds are just one. Adding chemistry to the vibratory process keeps the media and parts clean, enabling the media to accomplish its intended purpose. Because the variety of metals in the vibratory process, chemistry is needed to brighten and polish parts and to reduce cycle times

Our Chemtrol Advantage is having a chemist who has been dedicated for 35 years to developing compounds for the vibratory process and being able to formulate, craft and test our compounds under one roof. This dedication has enabled us to properly develop the best, most cost effective formulae to achieve your part’s specifications.

Chemistry is a very integral part of the vibratory finishing process. In order to achieve an acceptable part you must introduce a compound into the process.
These compounds consist of :
• Abrasives
• Adding abrasive reduces cut cycle times and can be used to improve the RMS finish of the part
• Burnishing
• Adding burnishing compounds generate brighter and cleaner parts and can assist in running delicate parts.

Alkaline cleaners
Oil and dirt are a detriment to the finishing process and must be removed. Using an alkaline cleaner assures the cleanliness of the parts and the effectiveness of the media.

Rust Inhibitors
Since the vibratory process is mostly a wet process the use of rust inhibitors is necessary to protect the parts after finishing.

Accelerants
The introduction of accelerants into vibratory compounds has enabled the process to achieve very low RMS finishes within greatly reduced time cycles.

As you can see compounds are widely used in the vibratory process and this is paramount to obtaining acceptable finishes. Our dedication to continually develop these compounds is how we are able to help our customers achieve their finishing requirements.

Jeff Bell
President
Precision Finishing Inc.

Posted in Finishing Compound Formulations, Vibratory Compounds | Leave a comment

Precision Finishing Company Overview

Posted on July 27, 2011 by Precision Finishing Inc.

Since 1955, Precision Finishing has been supplying creative, cost effective solutions for surface finishing and conditioning to the metal working industry. We take the time to listen, ask questions and truly understand what our customers needs are. Our years of experience and attention to process development provide the foundation for recommending the most cost effective means for finishing your part.

Whether you need vibratory deburring, blast cleaning, washing or waste treatment we have the ability and experience to help you.

We are in our second generation of doing what we do best – evaluating and recommending the most cost effective means of finishing your part.

We have expanded our relationships with the industries best known suppliers by acquiring Checker Industries in Pittsburgh, Pa. to assure you of access to the latest technologies available.

The uniqueness of our company is we have three business components all working together offering the best solutions for our customers.

  • Vibratory and blasting cleaning contract shops
  • In-house manufacturing of CHEMTROL vibratory
    and industrial washing  compounds
  • Direct sales of Vibratory and blasting cleaning
    equipment and supplies

We have what it takes to assist you. Our two contract facilities provide the platform for testing and evaluating blasting and tumbling medias used in the finishing process. 

Our onsite chemist gives us the unique ability to create, craft and then test our Chemtrol formulations in our own production contract shops. This versatility provides the ability to address an array of customers requirements.

We have the equipment and supplies for you to do it yourself. We offer all types of automated finishing equipment such as vibratory bowls, centrifugal barrels and disk equipment. In addition we stock a wide variety of finishing medias. 

We are a complete source for Blast Cleaning equipment and supplies. Whether your application requires a standard hand cabinet, blast room, complete automation, or airless blasting, we have the equipment and materials to meet your needs.

As you can see, by providing the facilities as well as the supplies –  either we can do it or you can do it.

With Precision Finishing you now have choice to achieve the most cost effective solution available to meet your particular requirement.  For all of your finishing needs Precision Finishing can guide you to the best, most cost effective solution.

Please send us an email or give us a call to discuss your next project or application

Jeff Bell
President
Precision Finishing Inc.

Posted in Chemically Accelerated Surface Finishing, Finishing Process | Leave a comment

Six Hints to Make Your Finishing Process Faster – Part 2

Posted on June 22, 2011 by Precision Finishing Inc.

To pick-up from the last blog post…here are three more hints to help your finishing process to reduce the time it takes to finish your parts:

4. Research Compound Formulations That Will Speed Up Your Process.

Compounds exist in many formulations to provide a variety of finishes. Researching different formulations than you’re currently using may enhance the capabilities of your media. Contact a reputable developer of finishing compounds to discuss your needs, what you’re currently using, and to get their help in determining which compounds may assist the speediness and quality of your unique finishing process. Taking the time to research alternatives will ensure you’re using the best compound for the exact finish you desire.

5. Utilize A Compound To Combine Processes.

Compounds are available that take a two-step finishing and washing process and combine them into one step, thus eliminating the expense of purchasing two compounds and the

time it takes to complete the finishing process. Deburring and rust inhibition can also be performed in one process, if the correct compound is selected. Again, a developer of multiple compounds can assist you in identifying compounds that achieve more than one purpose and combine multiple steps of the finishing process into one.

6. Weigh The Option Of Outsourcing Your Finishing Process.

With production levels varying more frequently these days, outsourcing can be the perfect solution to trying to manage your staff and keep them productive. Experts can take the process off of your hands and offer greater scalability for expansion and contraction of your finishing demands. Additionally, when you outsource your finishing process to another company, the waste treatment issues involved with finishing become their problem, not yours. Most professional finishing facilities house their own waste treatment systems because of the massive quantity of finishing they do and the amount of waste they deal with daily.

Jeff Bell
President
Precision Finishing Inc.

Posted in Finishing Compound Formulations, Finishing Process | Leave a comment

Six Hints to Make Your Finishing Process Faster – Part 1

Posted on June 15, 2011 by Precision Finishing Inc.

Part 1
Often times, individuals are aware that their process for finishing parts isn’t efficient, but they don’t know how to begin to fix it. We’ve put together an outline of six steps that will each assist in reducing the time it takes to finish your parts.

1. Examine Your Production Line For Efficiency Opportunities. Are the parts you are finishing in your facility reworked or scrapped frequently? Waste from an inefficient production line can be extremely costly – both in materials and in the time it takes to finish new parts to replace the ones that weren’t right. Are the goals of meeting production quotas causing your floor to produce insufficient finishes? When a production process is thoroughly reviewed for efficiency opportunities, changes often will result in parts being finished faster or right the first time – thus making achieving quotas without sacrificing quality a reality.

2. Tour A Professional Finishing Facility. By touring a professional facility, you will be exposed to new finishing techniques, media and compounds that may be very applicable enhancements for your finishing process. You’ll have the opportunity to see how experts approach the finishing process, and learn best practices approaches. By touring a professional finishing facility, you will gain: Tips and techniques on how to improve your process. Exposure to new machinery, media and compounds in action. The opportunity to ask questions about your finishing process and understand new improvement ideas you can take back to your facility.

3. Consider The Alternatives: Blasting Vs. Vibratory. Consult with an expert to make sure you’re using the right process for your parts. We frequently speak with individuals utilizing one process, when in reality the other would be more efficient for their needs. How do you figure this out? Invite an expert to come to your site and examine your process. Many finishing companies will offer this service – just ask! Stay tuned for three more hints to make your finshing process faster later this month…

Jeff Bell President
Precision Finishing Inc.

Posted in Finishing Process, Isotropic Finishing, Mass Finishing | Leave a comment

Sample Processing

Posted on May 28, 2011 by Precision Finishing Inc.

Sample processing is providing a finish on a sample part through a process of testing to achieve the specifications required. The testing establishes the process or processes which meet the customer’s requirements.  These processes can be many different types including tumbling, blasting and more.

The way we approach the sampling process is by concentrating on listening, very carefully and truly understanding the customer’s needs.  We then bring the physical piece into the company and bring together all of our experience and knowledge to the table. By having multiple people with vast experience involved there is no tunnel vision and open discussions take place to look at several ways to approach the finish. This collaboration develops the best way of testing to achieve the specifications of the customer. Precision Finishing is 1SO certified and we follow a standard process when documenting our sample processes.

We also look at the customer’s capabilities to see if they can do it in-house and the associated costs. Then we look at the option of having Precision do it.  We want to give the customer the information to assist them in making a sound business decision based on their specifications, production, quality and cost.

Three steps to start the Sampling Process:

  • Obtain sample parts and thoroughly understand the expectations of the customer. Finish, piece per hour, factory capabilities are some of the important criteria
  • Defining the process and testing.
  • Document and record all the information to pass on to the customer. The information will help facilitate the right business decision. 

The advantage of PFI is we operate a large contract shop for tumbling and blasting in the Mid Atlantic region and we develop and manufacture vibratory chemistry under the same roof.  We are able to utilize this experience when evaluating the variety of customer’s parts and needs. The most important aspect is our expertise, this is the key. If Precision does not have the capabilities in our facility, we keep the same ISO processes but the part is sent to one of our manufacturers to have the sample tested.

Top three things to consider during the Sampling Process:

1st – If the customer doesn’t have the capabilities then we help to establish a process. This saves the customer huge amounts of time and aggravation because they don’t have to send the part all around to many manufactures or venders to find out.

2nd – They will actually have a tangible sample part – it is not a theoretical process.

3rd – They will have enough information to make a proper business decision: keep the process in-house; outsource the processing or do not do it at all.

The sample process is really a feasibility test. We take the part from the stage of “you think you can do it” to “we did it”.  The sampling process is also a complimentary service to the customer. To this point, it is always better to involve finishing professionals in the beginning stages of the design process. This allows for more flexibility and up-front cost savings for the part.

Sean Duffy
Precision Finishing Inc.

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Mass Finishing 101 – Tumbling Finishing – Art versus Science

Posted on May 13, 2011 by Precision Finishing Inc.

Mass finishing which includes tumbling finishing is achieved by using one of several types of equipment to enhance the surface aspects of a metal part. This equipment ranges from tumbling barrels to vibratory and centrifugal finishing equipment. The process also involves a finishing medium, water and a chemical compound. The media can consist of ceramic, plastic, steel and agra-media depending upon the specifications of the part or the application.

The most common and most efficient piece of equipment used is vibratory finishing. This is widely used in the de-burring process. When you machine a part, it generates burrs. These are removed from the part in an economical method without having to do it by hand.

To determine the correct equipment, finishing media, water and chemical mixture to use is more of an art than a science. This is where sample processing takes place. The sample part is tested by going through several different processes to get the part with to the desired specification. The process parameters are developed based on knowledge of the process and past experiences.

During the parts test, Precision Finishing has a team that reviews the application. One or several processes are put down to be evaluated then the part is run through the testing process. Once the specification is achieved the part is sent back to the client for review and approval.

Bill Walker
Technical Director
Precision Finishing Inc.

Posted in Mass Finishing, Tumbling, Vibratory Finishing | Leave a comment