Mass finishing solutions tailored to customer needs
For tiny precision components with dimensions
Stüken, one of the world’s leading manufacturers of these products, meets this challenge with tailor-made equipment and carriers and compounds specially developed by Rösler. The solutions offered by Rösler guarantee a safe and risk-free deburring and rounding process and ensure that the customer’s surface finish specifications are fully met.
With a pioneering spirit, a forward-looking business philosophy, an innovative approach and the belief that effective solutions can only be achieved in a cooperative environment – with this business approach, Hubert Stüken founded his company in 1931. 90 years later, Hubert Stüken GmbH & Co. KG is the world leader in the field of stamped precision metal components. Stamped and bent parts, plastic-coated components and complex assemblies complete the product range of this family business which operates five manufacturing plants in Europe, the United States and China. Small high precision parts are usually not visible after assembly.
They are made from all metals that can be formed by deep drawing, such as stainless steel, copper, brass, aluminum, titanium and molybdenum. Stüken components are used in many technical products. For example, a fuel passenger car contains on average about 40 Stüken parts. For vehicles with alternative drive systems, this number tends to get even higher. The company’s components are also used in products in industries as diverse as electronics, information and communication technology, medical engineering, pharmaceuticals, household appliances and a wide range of consumer goods. consumption. However, they also play an important role in many other industries.
Joint development of solutions – also for surface finishing
To ensure that it can offer technically and economically optimal solutions to its customers, the company maintains its R&D and development department at the head office in Rinteln, Germany.
Andreas Hellmann, Sales Director at Stüken, said: “For many of our customers, we are a development partner. To perfectly adapt new products to their intended use, we not only work with our customers, but also cooperate with partners from various technology sectors. .“
The company has relied for 30 years on the experience and know-how of Rösler Oberflächentechnik GmbH for surface finishing problems that can be solved by mass finishing. The Sales Manager said: “Our partnership is based on the excellent quality, reliability and high availability of Rösler’s equipment, as well as the good technical service. We also appreciate Rösler’s comprehensive know-how and flexibility in developing solutions as a team. The advantage is that Rösler has a technical presence at all the sites where we manufacture our components.
At its manufacturing sites around the world, this stamping specialist uses approximately 15 rotary vibrators, 10 centrifugal disc finishing machines and 18 centrifuges to clean and recycle process water.
Stamped components are typically characterized by a high degree of material shaping, complex geometries, and extremely small dimensions requiring high dimensional accuracy. This results in particularly demanding specifications for deburring, rounding of edges and polishing of the external and internal areas of the workpiece. The requirements for surface roughness and surface quality are equally challenging.
Dirk Schulz, Project Engineer at Stüken, said: “On the one hand, we have to ensure that all parts of a part batch receive the same high-quality surface finish. On the other hand, the rate of chip removal on components with very thin walls and a large surface area must be limited so that the bulk finishing operation does not damage or deform them. In addition, after the completion of the finishing process, parts and supports must be reliably separated. A carryover of parts and/or supports into the next batch must be prevented at all costs! This not only requires precise adaptation of the finishing process to the workpieces. Likewise, the equipment and consumables must also be adapted to the workpieces and the finishing objective. Often this requires carrying out special feasibility studies.
Process development, equipment specifications and media selection
For new complex components, finishing processes are usually developed in the Rösler Customer Experience Center. This is equipped with state-of-the-art machinery that can perform a wide variety of different finishing processes. In extended processing trials, the most suitable equipment technology and machine specifications are set.
Tests frequently show that the generally smooth wear lining of the processing bowl of a mass finishing machine needs to be structured, in other words, needs to be a little rougher. „This prevents very small and light components from sticking to the wall of the processing bowl. In addition, to ensure complete and reliable separation of the finished pieces from the media, separation units and screens often have to be specially designed,” says Dirk Schulz.
Of course, the optimal adaptation of the type and shape of the ceramic or plastic carrier to the respective finishing task is equally important. To achieve consistently good surface finishes, the substrate very often must have extremely tight dimensional tolerances. In the final step, the process parameters, for example, the motor speed of the mass finishing machine, the batch size and the cycle time must be defined. In this regard, Stüken’s experience and know-how in the field of mass finishing play an important role.
Highly efficient cleaning and recycling of process water
The finishing operation is not the only factor that determines the quality and profitability of a mass finishing process. Equally important is the process water cleaning system.
The project engineer said, “The finishing process is the removal of materials from workpieces and fluids that contaminate the process water in the form of small metal fines and fluids. These fines must be reliably removed from the process water before they can be reused in the For this we use cleaning centrifuges, also supplied by Rösler.
The perfect technical adaptation of the Rösler centrifuges to the respective cleaning tasks guarantees a high cleaning effect, so that the cleaning process liquid can be recycled to the mass finishing process for reuse. This not only saves valuable resources, but is also very environmentally friendly. Optimal and consistent surface refinement of precision components manufactured with the deep drawing method requires perfect interplay between equipment technology, consumables and process water cleaning. Generally, the best results are achieved through close collaboration with the client.”