Simulation of blasting systems and processes Reduce costs and increase sustainability in blasting

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Blasting processes are indispensable in many industrial sectors. Regardless of the processing objective, the aim is to achieve the required blasting result in the shortest possible time, at the lowest possible cost and with minimal use of resources. Rösler meets these requirements through the use of state-of-the-art simulation software.

Whether it's cleaning blasting, deburring, pre-paint treatment or shot peening - blasting systems ensure the surface properties required for optimal further processing or product function in various applications. In these processes, companies face the task of improving productivity and cost efficiency and reducing energy and resource consumption. Rösler supports this through the use of the most modern simulation software for the design of blasting plants and the process design and optimization.

Results in line with requirements with the greatest possible efficiency

The simulation software allows all relevant physical processes of the blasting process as well as the workpieces to be processed to be displayed in 3D. This includes the fact that the type, amount, and flow of blasting media can be realistically simulated. The data generated in what's known as particle simulation allows precise statements about the amount of blasting material required and the energy with which it must hit the workpiece surfaces in order for a 100 percent coverage to be achieved. At the same time, based on this information, the necessary power and ideal positioning of the turbines in the blast chamber and corresponding workpiece holders can be defined. This results in blasting systems and processes that achieve the required result with the smallest possible number of turbines and a minimized energy input and wear. Investment and operating costs as well as resource consumption are thus minimized.

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Another advantage is that blasting systems for new components can be planned based solely on the CAD data of the workpieces - i.e. before real workpieces are available and the system can therefore be put into operation at the start of production. Time-consuming and costly tests with real parts are largely eliminated.

In addition, the simulation also provides insights into whether a component can be blasted in accordance with requirements in the given geometry. If this is not the case, the simulation results provide clues for component optimization.

Shorter planning time and improved process quality for large systems

The planning and commissioning of large blasting plants for components with a length of for example 20 meters, a width of five meters and a height of four meters and above, poses a special challenge. For workpieces with these dimensions, there are rarely facilities available for testing. The simulation and virtual verification of the blasting processes and results therefore make an important contribution to high process quality and efficiency for these systems. That's why Rösler has internally developed an additional tool for modeling appropriate systems and blasting processes. The realistic and correct depiction of the blasting patterns and blasting medium mass flows contributes to a high level of investment security on the one hand. On the other hand, the planning phase and commissioning of the plant take significantly less time.

Process bulk batches faster

In the case of blasting bulk material, for example in multi-tumbler systems (RMT), the mixing of blast goods and blasting media significantly influences the processing time and result. Here, among other things, the simulation of the drum-shaped blast chamber geometry allows the parts to be turned over more optimally, significantly reducing processing times. Concretely, this has already resulted in a time saving of around 25 percent per batch, which is equivalent to a corresponding increase in throughput.

Whether standard or large blasting plant - the filter system, along with the turbine, is one of the energy-intensive units of a blasting plant. Therefore, the air volume flow for extracting the dust created during blasting is also precisely examined by means of flow simulation. If the dust can be extracted more effectively through improved air guidance, the required filter size can possibly be reduced and energy saved. In any case, optimized extraction ensures shorter cycle times and thus higher productivity. In addition, the processed parts come out of the plant cleaner, which reduces the cleaning effort.

Digital turbine twin for efficiency improvement

In order to further reduce energy consumption and wear while increasing efficiency at the same time, Rösler works with digital twins of the blasting turbines. Through the complete integration of the particle flow, it can be virtually traced where wear occurs on the turbine and which geometric changes need to be made to minimize it. Corresponding simulations are also being conducted for a further increase in turbine efficiency, which contributes to additional energy savings.

Through the wide use of simulation technology both for the design of blasting systems and processes and for the optimization of extraction and turbine technology, Rösler's blasting systems are not only available faster. They also stand out due to their energy-saving and low-wear operation, thus providing the greatest possible customer benefit.

The development of vibratory grinding processes for the individual part processing of geometrically complex and difficult to process workpieces, such as knee implants, has so far required numerous series of tests. Therefore, such applications, for which a drag finisher is usually used, are also the focus of simulation technology at Rösler.