FC120 ZK - Alurodel Case Study Surface Finishing Machine

 

About Surface Finishing

Metal products usually have visual, aesthetic, or technical specifications related to their surface. Often surface finishing is required to meet those specifications, especially after the raw material has been transported, cut, curved, or drilled. All these processes create scratches, marks, and irregular surfaces which are normally not desirable on the final product. Grinding, chrome-plating, painting, brushing, or polishing are some of the finishes that are commonly seen. For most of these, a belt grinding or brushing process is required.

NS Máquinas produces a wide range of flat surfaces finishing machines equipped with different number of abrasive belt or brush stations are available in different widths and I wet or dry operation. Different options and accessories make these machines suitable for different type of finishing, grinding, and brushing applications, being used on a small production workshop or in a multiple shift production.   

   1) Raw flat bar without surface finishing

    2) Flat bar after metal grinding process with abrasive belt grit 60

 3) Flat bar after metal brushing process with an abrasive brush    

Defining a process

Considering the initial surface quality of the material and the required surface level is the most critical step when considering a metal finishing machine. This will determine the right equipment not only for the budget but also for the efficiency of the surface finishing process. NS Máquinas machines can be configurated with a different number of abrasive belts and brush stations. This can lead to a simple and low-cost tube or flat bar finishing machine with a single belt or brush station machine or, on the other limit, to a wet multiple head six stations machine. NS Máquinas can also offer through-feed top and bottom machines or even 4 sides finishing machines. These tubes and bar finishing machines will do 2 sides and even 4 sides simultaneously in one single pass, saving time and material handling costs.

 

The solution

The FC120 ZK machine is a Flat Surface Finishing Machine suitable for stainless steel flat bars and for rectangular tubes. This finishing machine can also process narrow metal sheets, flat metal parts and various other shapes such as door handles, knifes or, door locks.

This machine can be configurated with a single station – abrasive belt – or double station – abrasive belt and an abrasive brush. The 120mm width and 120mm height capacity is enough for most sizes in locksmiths, metal producers, metal finishing companies, metal components producers. The tools free and fast abrasive belt replacement system is an essential feature that allows the operator to quickly change the type of surface and continue with other work. For specific requests, this machine can also include loading and unloading tables, special conveyor belts for not flat components.

Putting the machine in operation and adjusting it was made very easy with a simple control panel where the conveyor belt and abrasive stations are switched on/off and speed adjusted. The machine also counts with a central thickness and pressure adjusting wheel with a 1/10mm precision display.

The model FC120 ZK features a non-woven abrasive brush which applies a smooth and regular finishing to the material. This brush has a wear adjustment wheel which enables a complete use of the abrasive right up to its core.

Below you can find the FC120 ZK demonstration video with rectangular and squared tubes, flat bars, and metal sheets surface finishing. 

The Case Study

Alurodel is a specialized sled manufacturer based in South Tirol, Italy. The aluminum sled is hand-made in their workshop. The company uses high-quality material to avoid rusting, scratching by humidity, or temperature change. Alurodel has purchased 2 months ago one FC120 ZK from NS Máquinas to help them in the finishing operation of aluminium frames.

In fact, at the production, the aluminum frame is one of the parts which requires special attention. Those parts are one of the most exposed to the snow (low temperatures) but also what allows it to slide and support the person's weight.

This company was finishing the aluminum surface to roughness of 3,5µm Ra with manual tools which were a very time-consuming process. NS Máquinas has proposed to achieve the same roughness on an automatic process with FC120 ZK. Setting the machine with a 60-grit abrasive belt and a medium grit abrasive brush, it was easy and quick to achieve a uniform surface which is perfect for the powder coating and clear coat required on the final product. Mr. Torggler, Alurodel general manager, points out that the company has increased 3 times the output of finished material, assuring at the same time a highly consistent production.

Alurodel aluminium sleds are a proven light, flexible, and secure item for pure fun to be used by the whole family. You may know more about this company and their products visiting their website.

 

Small Parts Polishing Machine - FGW170 2ZKR

FG and FGW lines, are capable to do: 

•         Flat bars grinding and polishing;
•         Rectangular tubes grinding and polishing;
•         Small parts grinding and polishing.

The machine counts with a 2ZK configuration for the grinding process: two abrasive belts stations and an abrasive brush station. The abrasive belt station includes a contact roller and two press rollers applying pressure in the metal surface. The brush, in the end, is able to reduce the lines and apply a polished effect. Also, the machine includes a water spray gun and filtration system which decreases temperature on the parts. 

In this case, the FGW170 2ZKR is special version for small parts surface processing due to the specific characteristics compared to the standard FGW170 surface finishing machine. The conveyor belt includes stoppers so the small metal parts can’t move during the operation. Also, in order to enable the operation by one operator and allow continuous flow of work, the machine was redesigned to include a parts return system. 

This feature consists on a rotary table and a return conveyor belt to bring the parts back to the feeding point of the machine. Therefore, the operator can be feeding the parts and, simultaneously, collecting and storing them. This system is also suitable for a fast double-side finishing of elements which need to be polished on both sides, once the operator can flip the parts and re-feed them on the machine.

Ramp and rotary table

After the grinding and polishing process, the metal parts fall through the ramp to the rotary table in order to reverse the route of the parts.

Extra conveyor belt

The parts now go to the return conveyor belt to bring the parts back to the feeding point of the machine.

Table for parts after finishing process

After all the process, the operator can flip the parts and fed them again into the machine or be stored.

Flat bars and rectangular tubes operation

Feeding rollers adapter can be also included in order to bypass the rotary table and to enable the finishing of long flat bars and rectangular tubes.

If you want to make some grinding and polishing tests in the machine please contact us through marketing@nsmaquinas.pt or through our website https://nsmaquinas.com/contacts/.

TR120 2Z Stainless Steel Edge grinder

Side grinding of stainless steel bars

“The TR series of machines from NS Maquinas are designed specifically for grinding of the edges on Stainless steel flat bars.

The machine utilizes a feed table, with downward facing pressure rollers to keep the material firmly against the conveyor feed belt and simply flows the material in a horizontal position past the linishing heads grinding a clean mechanical surface value on to the material.

The material is pushed against the linishing heads by 7, sprung loaded pressure rollers and has the capability to grind the edge of plate up to 300mm wide.

Ease of use is paramount in the design of TR series equipment. The abrasive linishing heads independently oscillate up and down, eliminating waste on the abrasive belt and ensuring that the maximum width of the belt is always consumed. The grinding head contact wheels are constructed of Nitrile, a robust, heat resistant material that offers long and durable service life. These wheels are manufactured at 90 Shore and run a serrated face to maximise the abrasive cutting action.

The standard TR machine is also fitted with flap wheels on the outgoing feed side, this lightly de-burrs the sharp edge that can be created when grinding the edge of flat bars, this task, is done in one action as the flat bars feed through the unit.

Adjustment of grinding pressures is easily and independently adjusted by the operator as they stand in front of the machine.”

By Corey Munn, NS Máquinas in Australia

For more information click HERE or email marketing@nsmaquinas.com.

Aluminium Profiles and Stainless Steel Flat Surfaces Finishing Machine

  

FGW170 4ZV is a machine for aluminium profiles finishing and satinising. Also this polishing machine is suitable for stainless steel flat bars and rectangular tubes finishing with 170mm width capacity, enabling feeding of multiple tubes at same time.









This machine has 4 abrasive stations, 2 working from the top and 2 from the bottom, enabling the complete outside surface to be finished in 2 passes only. Additionally, with the part returning mode, the operator can have the polished profiles back on the feeding point without having to return them manually. This makes the surface finishing work on tubes and profiles much more productive than with standard equipments.

FGW170 4ZV combines high output with flexibility of work. In this machine the operator has the possibility to replace abrasive belt per brush unit. Polishing curved or flat shapes of aluminium profiles is possible either with abrasive belt with special contact roller or with abrasive brushes. More, the 3 conveyor belt system enables the use of only top or bottom stations, increasing the range of applications of this tubes and profiles polishing machine.

FGW170 4ZV has water cooling working in closed circuit with an integrated automatic filtering and pumping system. This equipment easily slides outside the machine whenever cleaning or paper roll replacement is needed.

This finishing machine has a touchscreen control where all functions can be set from abrasive belt speed, profile feeding speed, selection of stations to operate, motors consumption and pumping system. Also, several programs with different combinations of settings can be saved for future use.

On the demonstration video available at www.nsmaquinas.com you may see several aluminium profiles are polished and it is also demonstrated stainless steel bars and square tubes finishing.

For any doubt contact us at marketing@nsmaquinas.pt

Sports Bars Polishing Machine: Curved Square Tube

Belt finishing or polishing tubes is often a requested operation for surface preparation prior to painting.

In this example we polish with ML100 tube finishing machine a square sports bar for a off road car. This sample is 30x30mm and in a 2 steps operation the four sides of the tube are completely polished, leaving the surface ready for paint coating.

The process is done without having to remove the tube out of the machine. By using the flexibility of the abrasive belts in the end of the 2 first sides of the tube, the product is simply rotated and polished back on the machine.

Check this demonstration video or contact us at marketing@nsmaquinas.pt

TR120 Z2L Side Grinding and Edges Deburring Machine

TR120 is the new solution for side grinding of bars and metal sheets leaving soft corners at same time.

This throughfeed machine has one horizontal abrasive belt head with vertical motorized oscillation along the 120mm of belt width. In this way the edges are perfectly grinded and the abrasive belt is used in its entire width.

After the belt unit there are two lamella wheels rotating in opposite direction and hitting top and bottom corner of the bar or metal sheet at same time. This system creates a rounding and smooth effect on the corners breaking sharp edges as NS LR30 deburring machine does.

Maximum thickness capacity is 20mm for flat bars side grinding and its starts practicaly in 0mm for metal sheeds deburring.

For more information contact us at marketing@nsmaquinas.pt

Large Square Tube Finishing & Wide Sheet Metal Polishing Machine

FGX650 is a Wide Belt Metal Finishing Machine ideal for finishing, satining, brushing and polishing square and rectangular tubes as well as metal sheets.

With a maximum working capacity of 650mm width, this Finishing Machine is equipped with one abrasive belt unit and a oscillating brush.

In tube finishing this machine can be used for hairline finishing оr satin finishing of multiple tubes at same time. Also, the feeding speed is controlled by frequency converter, allowing the metal finishing job from 2 up to 10 meters per minute.

On sheet metal work FGX650 polishes metal plates from 1 mm thickness with maximum consistency.

This metal finishing machine can also be used for polishing laser cut parts. More the oscillating brush enables light deburring of sharp edges.

Other models for narrower, but also larger dimensions are available.

On the video below you may see examples of square tube finishing and sheet metal finishing demonstrations.

Contact us at marketing@nsmaquinas.pt for more details

Flat Finishing: 2 Sides in 1 Pass Only

Finishing long square tubes or flat bars can now be done faster and with less handling.

After FGWH150 8Z, making the 4 sides of the profiles in 1 single step, FG220 4ZV is now an option for companies which want to decrease long tubes processing time.

This new throughfeed flat finishing machine combines 2 abrasive belts on the top and 2 on the bottom, making possible the work of 2 opposite sides at same time.

The standard maximum capacity of this machine is 220mm width per 200mm thickness and is capable of polishing long tubes and bars from 700mm.

Below you have the demonstration video where you can see 100x100 tube finishing and other flat finishing applications. For higher productions check FGWH150 8Z article.

More information marketing@nsmaquinas.pt or http://www.nsmaquinas.com/

4 Sides Square Tube Finishing

Conventional flat finishing machines for steel or stainless steel square tube and bars only enable the abrasive belt work in one side at each time. Tubes and bars have to be returned and flipped around 3 times in order to get all 4 sides finished.

In the most demanding productions, where operations, time and handling have to be minimized, this represents a high cost procedure.

In order to bring these costs down, NS has developed FGWH150.8Z flat finishing machine. This model was developed for continuous and intensive finishing of square tubes and bars in one step only, making this finishing machine especially interesting for tube producers, tube wholesalers and tube finishing companies.

Combining 4 sets of double abrasive belts, this 8 stations belt grinding machine makes the job in each side of the profile in few seconds without having to transport it back.

FGWH150.8Z square tube finishing machine has every station independently regulated and is wet refrigerated on the abrasive contact points, enabling a soft tube finishing without bending or deforming the material. The water flows in a closed circuit and is filtered in an automatic station, providing a longer life of the machine and its components.

The standard capacity of this flat finishing machine is 150mm width per 100mm thickness, but other configurations can be also available and adjusted to different product specifications.

Get more information at http://www.nsmaquinas.com/ or email NS at marketing@nsmaquinas.pt 

Heavy Duty Flat Bar Grinding & Square Tube Finishing

FGW Heavy Duty Flat Grinding Machines were thought for the most demanding applications where removal capacity of the finishing machine in poor quality stainless steel tubes is critical.

Below NS Australian Partner and metal finishing expert, Corey Munn, describes the benefits these models brought to stainless steel square tube and bar finishing.

“The FGW 2Z Tube Finishing Machines has been designed with great ability for rapid plate grinding in mind. The structure of the unit is second to none, giving no chance of flexing under the heavy workload that the machine can offer.

In the Asia pacific region, we’re commonly faced with stainless flat bar stocks that have poor heavily pickled surfaces. These surfaces require an exceptionally heavy cut to be removed completely in order to start the process of achieving the desired surface value.

With a combination of high horsepower motors, specifically designed contact rollers and brutal strength in its construction, the FGW Flat Finishing Machine delivers a package that can run all day, tearing through length after length of stainless bar, yet the same unit is able to bring the surface down to incredibly fine finishes by using various agglomerate style belts, we’re commonly running P600 – P1200 with great result.

Pressure rollers will keep the work piece secure, while a flood of coolant will keep the heat at bay, avoiding warping, twisting and curving allowing the 2 grinding heads to do what they were designed to do, finish and finish fast…We’re very happy with the FGW Square Tube Finishing Machine and look forward to placing more units in Australia in the near future.”

More information emaul us at marketing@nsmaquinas.pt