A deflashing media with high dimensional stability, which is also tough at low temperatures, is impact and abrasion resistant

Transcription

1 A deflashing media with high dimensional stability, which is also tough at low temperatures, is impact and abrasion resistant

2 Your Benefits at a Glance Emsodur, with its excellent properties such as high impact strength, abrasion resistance and dimensional stability, its cubic shape and consistent high quality is one of the best deflashing media products on the market. Lower operating costs Extremely low abrasion hence extended operational life when compared with other plastic media. Low media costs - A product of lower consumption rate X price per volume consumption. Faster throughput of parts thanks to its cubic shape A cube shape has 27 % more mass than a cylindrical shape of the same diagonal body measurement and therefore produces 27 % more kinetic energy.. A cube having 8 corners and 10 additional edges compared to a cylinder proves to be a more effective deflashing media shape. Preservation of original surface Effective deflashing without destroying the surface of the part being blasted: EMSODUR is not hard, it simply does not crack. Practically no dust formation. No colour contamination when blasting parts of different colours - Emsodur does not pick up pigments. Does not leave oil deposits, as is the case with some vegetable based blast media. Dimensional accuracy and stability of quality Each batch is checked for size and quality, production is permanently monitored. The high dimensional accuracy eliminates the risk of over-length particles jamming in the component. The stability of quality is guaranteed in the production of Emsodur by using prime raw materials. Emsodur is not made from low value ground, sifted or molten, cut waste. Dimensional accuracy and high quality guarantee uniform and repeatable blasting results. This is of prime importance for «New Generation», continuous blasting processes.

3 Marvellous Variety Emsodur has been specially developed for deflashing applications in collaboration with leading manufacturers of deflashing machines. Even though polyamides already feature good abrasion behaviour, high abrasion resistance has been a special target in the development of Emsodur products. In addition, other properties, as demanded by the deflashing industry, such as high impact strength, stability of form, dimensional accuracy, consistent quality, low dust formation, are integral characteristics of Emsodur products. Over the years special Emsodur grades with supplementary properties have been developed. E.g. Emsodur S - which is resistant to extremely low temperatures, Emsodur GV - a reinforced, more abrasive type and the fine grain Emsodur Micro type, with particle dimensions of between 200 and 400 microns. As a cost reducing alternative for deflashing rubber parts Emsodur AG introduced a polycarbonate deflashing media which, in comparison to other available media base on polycarbonate, shows extremely long durability. A large variety of Emsodur deflashing media is therefore available meeting the demands of almost any possible application.

4 Deflashing Thermoset Parts with EMSODUR N, EMSODUR GV Long usage life Deflashing media should never be compared to each other by means of short time trials. Some deflashing media develop fine surface stress cracking after lengthy use and then suddenly disintegrate. EMSODUR may become rounded at the corners, but does not break. This means the number of effective granules remains higher for a longer time period when compared to other known deflashing media. In addition, the extremely low abrasion of EMSODUR results in very little dust generation. Loaded with energy EMSODUR granules have a cubic shape. Therefore, when compared to other angular or cylindrically shaped blasting media, EMSODUR has more mass and achieves higher levels of kinetic energy. The result: A better deflashing performance is obtained without damaging the surface of the part. EMSODUR retains its ideal property profile even with the smallest particle sizes. Impact Energy EMSODUR (+27%) Cylindrical Media Economical Because they are poor conductors of electricity, plastic deflashing media build up a static electrical charge through the effect of friction. EMSODUR N and EMSODUR GV absorb water at a higher than average rate which increases their dielectric conductivity. To improve this effect EMSODUR contains an anti-static compound. Using EMSODUR lowers the consumption of expensive anti-static additives markedly and also reduces the loss of deflashing media caused by clustering of media particles. Additionally, dustless blasting results are achieved, saving on expensive post-treatment cleaning operations. EMSODUR is particularly suitable for use on deflashing machines made by Rosler AG in CH-5054 Kirchleerau. info@rosler.ch

5 Stability of quality Stability of results Modern deflashing operations are executed on continuous processing lines. In many instances media deflashing machines are integrated directly into the production process. In order to avoid fluctuations in deflashing quality all parameters must be kept constant. This is not possible when using deflashing media produced from waste material of varying compositions or having a random granular structure. EMSODUR is produced from prime raw materials only and is continuously checked during the production process for dimensional accuracy, stability and quality. Surface aspect and absence of dust Thermosetting plastics obtain their final surface finish and appearance during the injection or compression moulding production process. For this reason the surface finish of components must not be damaged, marred, dulled or dusted during the deflashing process. EMSODUR N guarantees that surfaces are left intact due to its high elasticity. What s more, the very low abrasion of EMSODUR ensures absence of dust and prevents expensive posttreatment. More mass Higher kinetic energy Many thermosetting plastic mass-produced mouldings have corners, edges, slots and holes thus limiting the maximum permissible size of the deflashing media particles. Smaller sized deflashing media particles having a cubic form, provide 27%more mass which improves performance compared to cylindrical shaped deflashing media.

6 Deflashing Rubber and Silicone Parts with EMSODUR C and EMSODUR S Cryogenic requirements Flexible parts made from elastic materials such as rubber, silicon, PUR etc. can only be deflashed mechanically in a rigid state, i.e. at low temperatures. Particularly high demands are imposed on the deflashing media at such temperatures. It must retain its elasticity longer than the components which are to be treated whilst retaining its impact toughness and notch resistance, so as to avoid cracking of the deflashing media particles. Further, the deflashing media particles must not be too hard in order to avoid damage to the brittle, sensitive parts being deflashed. Deflashing Rubber Parts with EMSODUR C Rubber parts are usually deflashed between -20 C and -140 C. EMSODUR C was introduced as a cost effective alternative to our EMSODUR S and features excellent properties at temperatures down to -140 C. Deflashing Rubber and Silicone Parts with EMSODUR S EMSODUR S is a special grade of deflashing media designed to meet cryogenic requirements at very low temperatures. Silicon parts are generally deflashed at far lower temperatures than rubber parts. EMSODUR S retains its profile of outstanding properties at temperatures around C. It proves extremely high impact strength, dimensional stability and resistance to abrasion. EMSODUR S is especially suitable for deflashing parts used in medical applications. EMSODUR S is free from bisphenol.

7 Precision Every deflashing process for low temperature, rigid rubber components entails the risk of an increased number of rejects. This is particularly evident when blasting with steel shot where even a slight exceeding of the blasting times leads to rejects. Thanks to its good abrasion resistance EMSODUR S can greatly reduce the risk of rejects. Even the finest of rubber parts with a wall thickness only a little greater than the flash itself can be treated with a high degree of precision and safety. No mouse-grey discoloration Undesired discoloration of rubber parts giving a mouse-grey hue when deflashed for example with steel blasting grit is a widely known phenomenon. Post-treatment, very often with chemicals, is then required to restore the original appearance of the parts. EMSODUR does not carry the effect of discoloration, and hence such costly and time-consuming posttreatment is unnecessary.

8 Deflashing of delicate components with EMSODUR Micro Small parts, big problems! Economic deflashing of small electrical components, computer components, circuit boards etc. has so far posed an unsolvable problem. On the one hand the size of the deflashing media particles must not exceed 400 µ due to the fine structure of these parts; on the other hand the size must not fall below 200 µ as this would have the effect of dust formation. Plus the kinetic energy is then too low. Easily solved Deflashing media known to date within this dimensional range consist of ground materials such as walnut shells, thermosetting plastics etc. These media are unsuitable because they fracture, producing an excessive amount of dust. The grit fragments are too aggressive and irregular in dimension. EMSODUR Micro is the only known deflashing media of this type which fulfils all demands regarding dimension, shape and performance. EMSODUR Micro has a long operational life span and does not cause harm to sensitive surfaces due to its elasticity. Dust formation is also considerably reduced. EMSODUR Micro improves your processing safety in deflashing small electrical parts and lowers the risk of rejects.

9 EMSODUR at a Glance Product Assortment: EMSODUR N EMSODUR N Cubic Natural, red EMSODUR N Cubic Red EMSODUR N Cubic Natural, red EMSODUR N Cubic Natural, red EMSODUR N Cubic Natural, red EMSODUR N Cubic Natural, red EMSODUR N Cubic Natural, red EMSODUR GV EMSODUR GV Cubic Natural EMSODUR GV Cubic Natural, red EMSODUR GV Cubic Natural EMSODUR S EMSODUR S Cubic Natural EMSODUR S Cubic Natural, red EMSODUR S Cubic Natural EMSODUR S Cubic Natural EMSODUR C EMSODUR C Cub. / Natural

10 Cyl. EMSODUR C Cubic Natural EMSODUR C Cubic Natural EMSODUR C Cubic Natural EMSODUR C Cubic Natural EMSODUR Micro EMSODUR Micro Granular µm Natural EMSODUR Specialities EMSODUR N Cubic Natural EMSODUR N Cubic Natural EMSODUR N Edged 1.0X1.0X X X12 Natural Specifications Type Density [kg/dm 3 ] Hardness Shore-D Rockwell Mohs EMSODUR N EMSODUR GV EMSODUR S EMSODUR C Packaging EMSODUR is supplied in bags containing 20 kg net.