When it comes to achieving a precise surface finish on your parts, selecting the right vibratory tumbling process is essential. The process involves multiple factors, including the right machinery, media, and compound, all of which contribute to consistent and repeatable results. To make an informed decision, running finishing trials is crucial. In this first part of our two-part blog series, we will explore the first three steps to set up a vibratory finishing process in the correct way.
Step 1: Gather Information About Your Part
The success of any vibratory tumbling process starts with understanding the characteristics of your part. You need to collect critical information such as:
- Material
- Dimensions
- Shape
- Weight
- Surface Roughness
- Manufacturing Volumes (per day/month/batch quantities)
- Current Process Issues (costs, poor finish, long process times, high scrap rate, rework requirements, etc.)
- Process Requirements (deburring, descaling, radiusing, polishing, edge-breaking, etc.)
By compiling this information, you can determine the finishing requirements, the batch size, and the challenges that need to be addressed to improve your finishing process.
Step 2: Determine the Best Machine for Your Vibratory Tumbling Process
Choosing the right finishing machine is crucial for achieving the desired results. Here are some common vibratory finishing machines and their applications:
Vibratory Trough Finishing Machine
- Ideal for large, long, and irregular-shaped parts.
- Available in various sizes with adjustable lengths and widths.
- Suitable for deburring, descaling, radiusing, cleaning, and polishing.
- Can include divider plates for processing delicate parts separately.
- Manual or automatic part separation options are available.
Vibratory Bowl Finishing Machine
- Suitable for small to large batch processing.
- The polyurethane-lined chamber ensures efficient tumbling action.
- Ideal for deburring, descaling, radiusing, cleaning, and polishing.
- Customisable to include manual or automated separation systems.
- Some models include a pneumatically operated discharge door for part-on-part finishing.
Vibratory Dual Finishing Machine
- Integrates two chambers: one for wet processes and another for dry processes.
- The inner chamber is used for deburring, descaling, and polishing.
- The outer chamber is designed for drying or polishing parts using agro media.
- Typically includes a separation system for efficient media and part separation.
Dryer Machines
- Used for drying components after finishing.
- Options include conveyorised drying ovens, vibratory dryers, rotary dryers, and centrifugal dryers.
- Selection depends on part size, batch size, and space limitations.
Step 3: Calculate the Batch Size for Your Vibratory Tumbling Process
To determine the correct batch size, you must calculate the media-to-part ratio. This requires knowing:
- Part volume
- Usable volume of the finishing machine’s work chamber (which is typically 90% for a vibratory machine)
The guidelines below will help you in determining the right media to part ratio for your process:
| 0:1 | Part on part finishing (no media) |
| 1:1 | Equal parts of media and components; for a rough surface finish on castings, forgings or stampings. |
| 2:1 | A lower ratio of media to part, which can be used for very small parts; will still produce a rough finish on castings, forgings or stampings. |
| 3:1 | Minimised part to part interaction; great for moderate deburring and surface finishing on ferrous metals. |
| 4:1 | A good ratio for ferrous metals but average for non-ferrous parts; also minimised part to part interaction |
| 5:1 | A minimum part on part interaction; great for non-ferrous and softer materials |
| 6:1 | Used when processing non-ferrous and fragile parts for pre-plate and decorative finish |
| 8:1 | Recommended for bright burnished finish and high quality pre-plate finish |
| 10:1 | Great for finishing parts with irregular shapes and fragile components |
In the next part of this series, we will cover setting the machine amplitude, selecting the right media, choosing the right compound, and running finishing trials. Stay tuned for more insights into perfecting your vibratory finishing process!