Consumables for vibratory finishing

Quality vibratory finishing depends not only on the equipment, but also on the right consumables. For context see what is vibratory finishing.

What consumables are needed?

• ceramic media — for intense grinding and deburring;
• plastic media — for fine finishes and sensitive parts;
• porcelain media — for polishing and smoothing;
• urea — for specific processes;
• detergents and compound — for cleaning and process control;
• flocculants — for treating the process water.

How to choose?

The choice depends on the part material, the desired result (deburring, smoothing, polishing) and the equipment type.

Seven questions before choosing a compound

Choosing a compound does not start from the catalogue, it starts from the part and the machine. Seven answers and the list narrows to two or three options:

• does the part material rust?
• does the part arrive with oil on it?
• what cleanliness is required afterwards — is welding or painting next?
• is it a special process (pickling, ball burnishing, superfinishing)?
• are plastic media in use?
• is the water recycled or sent to drain?
• does the customer have their own environmental or quality rules?

The welding and painting question is the one most often forgotten. Corrosion inhibitors leave a film on the surface. Good film for storage, bad film for the adhesion of whatever comes next.

And one point that prevents complaints: no compound gives permanent corrosion protection. Long storage or overseas transport needs additional protection.

Water matters more than the compound

The same compound gives different results at two customers. Usually because of the water.

Soft water: excellent cleaning and emulsifying, good dispersion of solids — but heavy foam and no corrosion protection. Hard water: excellent corrosion protection, no foam — but weaker cleaning.

That is where the two compound families part ways. Soap-containing compounds depend on water hardness and work best at 8–15 °dH. Soap-free compounds are independent of hardness — which is why they are the first choice when the water varies or is recycled.

Two thresholds, valid on any recycling system:

• pH above 8.5. Cleaning, dispersion and corrosion protection only work above 7 to 7.5. Below that, the compound is in the bowl but not doing its job.
• Water temperature above 20 °C for soap-free compounds.

If the pH drops on its own, there are usually two causes: acidic fresh water (well water or DI water) or plastic media run at high amplitude. Correct it with a pH additive, not by changing the compound.

The flocculant follows the part, not the price

In water recycling, the flocculant separates abrasive and metal particles. The choice differs by case: one for oily water, another for low media wear, another all-purpose.

The exception that matters: rust-sensitive parts. There you either skip flocculation or use a chloride-free flocculant — chlorides attack exactly the parts you are trying to protect.

Effluent consistency differs from one installation to the next, so the right flocculant is settled on a real sample of process water, not from a catalogue. The sample has to be fresh: old water gives a different answer.

Conclusion

The right consumables make the difference between a good finish and an excellent one. VIBROBLAST offers ceramic, plastic and porcelain media, compounds and advice.