Surface International has been producing shot peening since January 2007. These machines provide a controlled shot blasting process, which serves to increase the fatigue life of various auto components subjected to high-reversing cyclic stresses.
DescriptionThe system consists of a blast cabinet for the purpose of external peening of gears.
•  The cabinet has two opening at front for entry and exit of satellite. Two side doors are provided for maintenance purpose.
•  Blast cabinet is lined with rolled manganese steel sheet from inside to protect it from wear and abrasion.
• A motorised indexing system is provided inside the booth. The indexing system has four satellite turntables.
•  The satellite at loading station and waiting station are idler while the other two satellites are revolving. The drive satellite is mounted outside the cabinet and transferred through chain and sprocket. Suitable fixture is provided on each satellite.
•  Three 15 and ½ inch blast wheel are mounted on back wall of cabinet at a suitable distance and angle so that hot zone is generated on gear surface.
•  At the bottom of blast cabinet, suitable capacity of screw conveyor is provided to convey the used shots to the boot of bucket elevator.
•  Bucket elevator with rotary screen separator is provided for reclamation and recycling of shots into the blast wheel through a sliding valve.• For the collection of dust particles, high-efficiency continuous cleaning pleated bag dust collector system is provided.
OperationThe operator places the set of gears on the idler satellite turntable which is in the horizontal position and presses the sequence start push button. The indexing turntable carries the satellite into the blast cabinet and starts rotating. At the blasting station, the position of satellite is sensed and sliding valve actuates to allow the shot flow. The peening operation is carried out on the gears for a predefined duration to achieve the required intensity. After completion of cycle, turntable indexes and the same cycle repeats.
During the peening, operation used shots falls into the screw conveyor provided below blast cabinet. From there, the shots are transferred into the boot of bucket elevator. The bucket elevator lifts the media and pours into the rotary screen separator where continuous screening is done to remove the debris from the blasted media. The screened media falls into the air wash type media separation system where the media is air washed to remove the dust particles from the usable shots and finally they are collected in a storage tank of suitable capacity for recycling to the blast wheel. The debris from rotary screen separator and unusable media from media separation system is collected in a bin (buyer to arrange bin).
A suitable size of ducting is connected among the blast cabinets to their respective dust collector. The dust and fines from blast cabinet are sucked and carried into the pleated bag type dust collector. The dust particles gets collected in the hopper and clean air is discharged into the atmosphere, keeping the environment clean and healthy. An auto replenisher is given which automatically add the media in the recovery line whenever the level of media goes below the acceptable limits.
Scope for Surface• Blast cabinet duly manganese lined from inside•  Entry and exit set of rubber vestibules• Motorised indexing turntable with braking arrangement•  Four satellites with rotational speed variation•   Three blast wheel 15 and ½ inches, 15  HP VFD drive and sliding valve•   Fully automatic media recovery system•  Bucket elevator with rotary screen type media separation unit•  Pleated bag dust collector with exhaust fan• Inter-connecting ducting and auto replenisher• Spring balance type shot classifier• PLC operated electric control panel with operator consol HMI and wiring.
Client’s scope•  Dry and oil free compressed air supply 35 CFM at 80 PSIG for pleated bag dust collector•  Dust disposal arrangement•  Separate earthing for control console.
Technical specificationBlast cabinetBlast cabinets are manufactured from prime quality heavy duty steel plate of 6 mm and 10 mm and mounted on rigid structural steel frame work. The blast cabinet’s internal surface is provided with rolled manganese steel liners. The blast cabinet is provided with 6 mm thick heavy duty perforated manganese steel floor for the transfer of shot to the hopper for recycling. The hopper is manufactured from heavy duty steel plate to mount the screw conveyor system.Length: 1,700 mmWidth: 2,000 mmHeight: 2,500 mm
A suitable opening is provided at the front of blast cabinet to facilitate the movement of indexing satellite turntable in and out of the cabinet. Set of rubber vestibules are provided to minimise the leakage of shots from the cabinet. Two hinged type doors at sides and one at back wall of blast cabinet is provided for maintenance purpose. A suitable opening will be providing in the hopper for removing the abrasive in any emergency. 
Indexing frame and armsA heavy duty indexing frame is mounted inside the cabinet. The complete frame is supported on a sealed bearing housing. The drive for indexing arm is mounted below the blast cabinet. The drive is transferred to the frame by a rigid shaft.
A suitable size of partition wall is mounted on the indexing frame between each satellite duly manganese lined from both sides.  A suitable capacity torque limiter will be supplied to avoid breakdown in hanger drive during falling of any component. Satellite turntablesOne satellite turntable is mounted on each indexing frame. The turntable is mounted in a sealed bearing housing to protect from dust and dirt. The satellite is lined with manganese steel liners to protect from abrasion. The satellite at loading and unloading station is idler and stationary. The drive for satellite is mounted outside the blast cabinet and power is transferred by suitable capacity of chain and sprocket.
Blast wheel assemblyThe blast wheel assemblies are mounted on a 12-mm thick plate. The wheel consists of fabricated steel casing, alloy steel liners, rotor, blades, control cage and feed spout. The rotor is made out of EN grade material duly hardened to the full depth. Blast wheel is coupled through self-lubricated and self aligning pedestal bearings. The rotor is dynamically balanced and the drive shaft of the blast wheel is made out of EN grade material and duly precision grinded.
Screw conveyorOne number screw conveyor is provided below blast cabinet. The screw conveyor hopper is fabricated from 6-mm steel sheet duly reinforced with thick steel strips. The trough is fabricated from 6-mm steel sheet and provided with perforated sheet to avoid any damage to screw conveyor and provision to remove the broken parts.
Spent shots falls into the screw conveyor hopper, which runs lengthwise and convey media into the boot of bucket elevator. The screw conveyor shall be fabricated from ‘C’ class pipe, with 6-mm thick flight.
Pleated bag dust collectorThe dust-laden air sucked from the blast cabinet enters into the dust collector. It passes through filter bags where the dust particles deposit on the surface of bags and clean air discharges into the atmosphere. The fabric bags are automatically cleaned with aid of automatic timer card through which solenoid valves are activated and compressed air blown into the bags at a time for cleaning the filter elements. The dust released from fabric bags is collected in the bin provided below the dust collector hopper.
The dust collector is fabricated from 14 gauge steel sheet in welded and folded construction, suitably reinforced for strength and rigidity.

Contact:Surface International, F-32, MIA, Phase-1, Basni,Jodhpur – 342 005, Rajasthan