Horizontal shot blasting machine

Types of horizontal shot blasting machines

A horizontal shot blasting machine is a surface treatment machine that uses high-velocity steel shots to remove rust, scale, and other surface contaminants from metal workpieces. Metalwork pieces, like steel plates, are blasted with shots in a horizontal environment. Here are a few types of horizontal shot blasting machines:

• Floor Blast Machines

  Floor blast machines are designed for easy loading and unloading of workpieces by operators. They typically feature an open floor area where users can place the items directly onto the blasting surface. An integral conveyor system then moves the item through the blasting procedure. Floor blast machines are quite useful for processing flat components, higher quantities of small parts, and ones with unusual shapes. They can also be used to boost efficiency in facilities.

• Spinner Hanger Machines

  Spinner hanger horizontal shot blasting machines utilize an overhead conveyor to suspend workpieces during the blasting procedure. This kind of machine is great for actively processing parts of varying sizes and shapes. A spinner conveyor keeps the workpieces moving while the blast wheels spin them to ensure uniform surface coverage. These machines are useful for quickly treating multiple components in a single procedure, and they deliver efficiency and flexibility when handling irregularly shaped items.

• Turntable Machines

  Similar to spinner hanger machines, turntable horizontal shot blasting machines are designed for blasting workpieces of different sizes and shapes. However, they come with a built-in turntable that rotates to expose all the parts of the workpiece to the blasting area. This makes sure that the entire surface of the item is blasted evenly. As one would expect, turntable machines are ideal for processing larger, heavier components that need to be rotated for proper blasting. They also have the advantage of not requiring the workpiece to be manually turned or repositioned during the blasting procedure.

Specifications and maintenance of horizontal shot blasting machines

Specifications

The machine comprises several components, each with distinct specifications: the control cabinet, the air compressor, the separator, the elevator, the filter bag, and the blast wheel:

• Control cabinet: This cabinet is usually equipped with open-circuit, fingertip sized components, distinct programming, and a spectrum analyzer. A variable frequency drive (VFD) is sometimes utilized to regulate motor speed or adjust the duty cycle.
• Air compressor: In a horizontal machine, the air compressor must be large enough to handle the required flow. For most machines, a 7.5kw motor with 0.700.65mpa is sufficient. Smaller machines will use 5.5kw motor compressors. A 5.5kw motor may work, but it will need more time than 7.5kw to perform the same work.
• Separator: The horizontal separator is usually a multi-stage cyclone that separates waste materials from reusable compressed air. It will have an inlet that connects to a horizontal shot blast machine and a sediment outlet directed to a horizontal shot blast machine filter bag. The sediment outlet will be the location where waste material collects. The separator may use a frusto-conical shape for the cyclone body and utilize gravity vorticities for separation.
• Filter bag: The filter bags can be either pulse-jet or manual shake filter bags. Pulse-jet filter bags are usually made of polyester fabric, while manual shake filter bags are made of glass fiber or aramid fiber. The number of filter bags in a cyclone shot blasting machine varies according to machine size. In smaller machines, there are usually 4-7 bags, but in larger ones, there can be more than 30.
• Separator dust fan: This variable speed fan operates according to the selector switch in the control cabinet or the blast switch. It is used to extract dust from the filter bags and direct it to the rear outlet of the separator. The model of the fan varies according to the machine it is fitted to. For horizontal machines, it is usually a 4kw motor.
• Elevator: The elevator receives the separated abrasive material from the cyclone base and transfers it to the horizontal separator's hopper. It does this through a bucket and chain system. The elevator is usually an upright column with a chain running through it to hold the buckets. The elevator speed will vary from machine to machine depending on how fast it needs to get the material to the separator, but generally, it is 2.5m per minute.
• Blast wheel: The components of this are the wheel housing, wheel hub, impeller, wheel spindle, and weapon. The hub and body are usually made of high-strength cast iron to carry out their function correctly, and the weapon is sometimes made of high manganese steel. The casing is also known as the wheel housing. It prevents stray projectiles caused by the centrifugal force in which they are ejected.

Maintenance

• Cleaning: This is the first step. By using a damp cloth and some mild detergent to wipe down the outside of the cabinet, any dust or foreign material can be removed, and a danger of interference from outside foreign material can be lessened.
• Inspecting internal components: After unplugging the machine and conducting other pre-maintenance operations, the user can open the cabinet door and inspect the internal components of the machine. Attention should be paid to the parts where electrical wires connect, as loose connections may be present. A similar inspection should be done to check other machine parts, like the air compressor.
• Blower dust or vacuum clean: In the case of some horizontal shot-blast cabinet models, users can use the blowout function to clean the inside of the cabinet. Others have a built-in dust extractor. For those without it, the extractor or back of the dust should be cleaned.
• Striking dust: If there is no dust extractor built into the cabinet, the shot-blast machine user's manual shake filter bag should be shaken or client instruction should be followed. If the user's manual is not to shake it, then the user's filter bags should not be shaken.
• Cleaning the air compressor: The horizontal air compressor will need to be emptied of condensate at least once a month. The separator in it filters out the water from the air. The horizontal blast filters can be drained manually, or some are automatic.

Applications of horizontal shot blasting machines

Many industries worldwide use horizontal shot blasting machines because they are versatile and reliable. The main horizontal shot blasting machine applications are discussed below:

• Cleaning Casting and Removing Oxide Scales

  Foundry industries use horizontal shot-blasting machines to clean castings. The castings usually have sand residues after the molds are broken. Also, when the cast metals cool, they form oxide scales that must be removed to enhance the metals' quality and appearance. Horizontal shot blasting machines use steel shots to remove sand residues and oxide scales quickly and efficiently, saving time and effort. Afterward, a clean and smooth surface is left on the metal casting.

• Surface Preparation for Welding and Coating

  A horizontal shot blasting machine enhances the surface of workpieces before they are coated or welded. By removing rust, dirt, and grease, it boosts the workpieces’ adhesive capacity to coatings and improves the quality of welds. Horizontal shot blasting machines improve mechanical bonding and ensure coating systems last longer and do not peel off.

• Surface Polishing and Texturing

  In the automotive and aerospace industries, horizontal shot blasting machines create textured finishes and polished surfaces on metal parts. Shot blasting improves the appearance of workpieces by achieving the desired matte or satin finishes. It also gives the workpieces decorative surfaces that enhance component integration, thereby improving their performance and aesthetics.

• Fatigue Strength Enhancement

  Many industries use horizontal shot blasting machines to increase metal parts' fatigue strength. The machines do this by introducing compressive residual stress at or near the surface of the metal parts. Components like turbine blades, springs, drive shafts, and axles that have been treated with a horizontal shot blasting machine have longer service lives because their resistance to fatigue failure increases.

• Cleaning and Surface Preparation for Surgical Instruments

  The medical industry uses small and delicate horizontal shot blasting machines to clean and prepare the surfaces of surgical instruments. The surfaces are meticulously prepared by removing residues and contaminants. Furthermore, horizontal shot blasting enhances the instruments' precision and functionality, showing the industry standard.

How to Choose Horizontal Shot Blasting Machines

There are many things people should consider before buying blasters for steel. They should first assess their needs. Determine the type of work that needs to be blasted and the capacity that is required. Consider the type of machine that will suit the intended use. People will also have to choose between the automatic and manual control of the machine.

The available space in the industry will affect the size of the machine to buy. Customers with small floor space will have to go for smaller machines such as the horizontal belt shot blasting machine, which comes in compact sizes. The budget also plays an important role in determining the type of machine one will choose. If one will go for a low-budget, low-capaityk machine, he will have to settle for a machine that is not as effective as a large-capacity, high-budget machine. It is also important to consider the type of maintenance and the replacement parts needed. Some machines will need more maintenance and more expensive parts to replace.

People should only buy machines from reputable manufacturers and suppliers with a good customer support system. Before making any transaction, it is important to read all customer reviews to see what other customers are saying about the product and the supplier. Take time and do thorough research before making the final decision.

Q&A

Q1: What are the key components of a horizontal blast machine?

A1: A typical horizontal blast machine comprises a pressure vessel, control system, bustle valve, seat valve, nozzle, air compressor, and blast wheel. These components work together to ensure an efficient blasting process. A horizontal pressure blast machine is different from a cabinet blast machine in that it stores the blast media in a pressure vessel.

Q2: What types of media are used in horizontal shot blasting Machines?

A2: Steel shot is a spherical cast steel answer used for horizontal shot blasting. The size of the shot determines the surface profile of the blasted part. Smaller shots create a finer profile, while larger shots produce a more textured surface. Other options exist, like steel grit, quartz sand, and steel cut wire.

Q3: How important is the control system in a horizontal shot blasting machine?

A3: The control system is the machine's brain. It manages the media's flow, pressure, and timing during the blast operation. An advanced control system allows for precise adjustments and can improve the machine's efficiency and safety.

Q4: What is the capacity range of horizontal shot blasting machines?

A4: These machines can handle different capacities, typically between 100 to 500 kgs per hour. The capacity defines the amount of work they can process in a given time.