August 2024 Volume 6

AUTOMATION

Implementing robotic surface finishing for metalworking operations in the forging industry can revolutionize efficiency, precision, and safety. By following some rules that include understanding the benefits, setting objectives, as well as selecting the appropriate easy-to-use tool tech nology, manufactures can achieve successful and sustainable implementation. Supported by fast process development with a reliable partner. AUTOMATED SURFACE FINISHING Unleashing New Possibilities By Michael Haas

Understanding the Benefits Before starting with automation, it‘s essential to understand the potential benefits of robotic surface finishing in metalworking opera

tions. These benefits are: 1) Improved Precision

Robotic grinding or polishing systems can be programmed to execute precise movements and to control parameters like constant contact force and speed, resulting in highly accurate and repeatable surface finishing processes, ultimately improving the quality and consistency of products due to minimized risk of error and re-work. 2) Enhanced Efficiency Automated systems can operate continuously, providing a consis tent, high-speed performance, which significantly increases overall efficiency and throughput compared to manual processes. Often, cycle times of any given process and abrasive costs will be signifi- cantly reduced. 3) Increased Safety By automating dangerous or repetitive tasks, the risk of injuries to human workers is reduced, creating a safer work environment, and minimizing workers complaints. Legal proceedings can be expensive and are better invested in your automation solution. These “3D” or “4D-jobs“ stand for Dirty, Dangerous, Demeaning, and Dull. While an automated process may not eliminate those roles completely, they can often take over 70-90% of those 4D jobs, allowing the work force to contribute to the business in other valuable areas. Letting the robots do the physically demanding job. 4) Cost Savings Besides the initial investment, automated systems can lead to long term cost savings and fast ROI due to reduced labor costs, increased productivity, and less consumables needed. Often, the greatest benefit is being able to retain your current workforce and channel their talent towards tasks or jobs that are of greater interest to them, and of greater value to the company. 5) Resistance to Workforce Fluctuations Having a robotic system in your manufacturing facility could help mitigate the impact of changes in workforce availability. Automated processes typically have higher output and throughput than manual labor and are capable of working multiple shifts daily. This means that the risk of stock shortages and underproduction due to work force fluctuations could potentially be reduced.

M aterial removal is a fundamental aspect of metalworking, encompassing processes such as grinding, sanding, finishing, polishing, deburring, and cutting. Most appli cations (in metal) are made after welding, forging or casting, but some can take place before, or even during the process, like: surface prep, cutting, or weld cleaning between passes. And it is not always glamorous work – polishing stainless steel to a mirror finish is just as essential as grinding down heavy flashing on a cast metal part – but both processes are time consuming, physically demanding, and require experience that is challenging for many companies to find, hire, and retain. It is no secret that many manufacturers have recently faced problems related to skilled labor shortages and increasing demands on the sustainability front. An effective way for them to think forward is to integrate automation systems in their plant processes. The use of more advanced end effectors, such as active force compliance devices can often work in such a way.

FIA MAGAZINE | AUGUST 2024 26