DieBlast Cryogenic Deflashing & Deburring Media Won't Work For Us

The last blog post I made was about the introduction of DieBlast Cryogenic Grade Polycarbonate Media into our facility. We were able to try a sample of both the .020 and .060 media.

Our first sample was a current part that we already run for one of our present customers using the .020 media. We split the order into three batches. One was using our current Maxi-Blast media for the original cycle time of ten minutes. Out of a set of 230 parts, 26 parts were rejected. This means that 12% out of 230 parts needed to be run a second time. You would think 12% was high but then we ran the DieBlast media.

When we were offered a sample of DieBlast, we were told that it reduces cycle times, and cycle rpms, as well as liquid nitrogen intake. No matter what we would not change the temperatures of our recipes. So the only way liquid nitrogen intake would be reduced is by shorter cycle times. We ran the same rpm for the throw wheel and a seven minute cycle instead of a ten minute. Out of 230 parts, 55 parts were rejected. So 24% out of 230 parts needed more time to remove all the burrs. Then we ran our third lot which was identical to the original recipe besides the fact that it was using DieBlast media. Out of 230 parts, 44 were rejected. 19% of 230 parts needed a longer cycle time.

Needless to say, I was surprised by the results and expected DieBlast to do a lot better. It failed to meet our expectations. Therefore, we will continue to use Maxi-Blast and Polyblast media that we have always used. Their media is very similar in shape and lifetime.

DieBlast Cryogenic Grade Polycarbonate Deflashing & Deburring Media

After a few weeks of waiting our new cryogenic grade media arrived for our cryogenic deflashing and deburring operations.

For the time being, we get to try samples of both .020 and .060 media by Dieblast. Dieblast is currently made in the United Kingdom. The media is different from it's competitors Maxiblast and Polyblast because the media is in a cube shape versus drum shape.

As a result, the media has 16 cutting edges versus 2 on the current media we have been using. The photo shows two piles of the Dieblast media. The .060 is on the left and the .020 is on the right. Next to both those piles are a sample of the current media we have been using.

Unfortunately, we haven't actually been able to run a sample using the Dieblast media yet. But, once we run a few samples with it, I will report back and post our results using this new type of media.

Electromagnetic Deburring Sample Success

The manufacturer of the electromagnetic deburring machine just ran some samples for us. Our contact there was very happy with the results. There was only one part out of the sample that wasn't fit for this deburring process. He was able to get all the holes and edges using the different kinds of media on the many parts we sent him. Run times were between 20 and 40 minutes, so we should be able to keep costs down. Large volumes will help with the longer cycle times to help keep price down as well. After a few more samples, if we continue to get positive results, we will be bringing this technology in house.

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Adding Better Metal Deburring & Surface Polishing Capabilities

Over time, we have realized that metal deburring is part of our business. Some metal products however do not get their burrs removed through our cryogenic deburring process. In the past few months, we have been researching an affordable machine capable of better serving our customers with metal and steel products for deburring.

One machine in particular that may fit our needs uses an electromagnetic current to excite a stainless steel media that removes burrs from both ferrous and non-ferrous metal. We are currently working with the machine manufacturer to have samples run by them. After we are assured that the machine is a good fit for us, we may be purchasing one in either September or October.

In the past year, we have realized the need for metal surface polishing as well. The beauty of this electromagnetic deburring machine is that it can be used for surface polishing as well. So, if the machine works for us, we will be able to deburr small metal parts. We will also be able to leave a clean finish for our customers' parts.

If you would like samples run by us, give us a call today at 800-739-7949. Our team would be more than happy to assist you with any of your deburring or surface polishing needs.

New Media for our Deflashing & Deburring Process

Recently, we were approached by US Abrasives to try a new type of cryogenic grade media. The media is made by Dieblast in the United Kingdom. For years we have been using Maxi-Blast media. Maxi-Blast media is circular in shape like a drum with only two cutting edges. Dieblast media is in the form of a cube and has 16 cutting surfaces. This should have a major effect on our cryogenic deflashing and deburring operation.

From what we have learned, Dieblast allows you to run at lower rpms, warmer temperatures, and shorter cycles. This means that our liquid nitrogen costs may be reduced along with our energy costs. The media is also supposed to last longer so we should be able to reduce our media consumption costs. If in fact the media works well, pricing for new customers may be able to be reduced due to shorter cycle times. Using this Dieblast media could be a win-win situation for us and our customers.

However, it isn't here yet. We are receiving two fifty-five pound samples next week in both .020 and .060 media. Once, we have ran a few samples using the new media, I will post an update. I hope for it to be a success.

Cryogenic Helium Processing

This is a press release that was made about a month ago. However, I wanted to add it to our blog, so that other people can see it.

Cryogenic Helium Processing Approaches New Levels of Affordability

Worcester, MA – June 30, 2008 – The Cryogenic Institute of New England, Inc. introduces a new capability of utilizing liquid helium for cryogenic treatment of materials to temperatures as low as 4K /-268C/-451F. Measurements were recorded by attaching a spring loaded silicone diode cryogenic temperature sensor rated to 1.4K with a calibrated accuracy of +/- 10mK.

The procedure involves the utilization of a specially modified cryogenic chamber that was designed and constructed in collaboration with technology partner Applied Cryogenics Inc. The chamber utilizes multiple dedicated delivery systems for introduction of both liquid nitrogen and liquid helium. The system also utilizes an advanced insulation scheme that involves a combination of sophisticated polyisoanurate materials, as well as vacuum and liquid nitrogen jackets for maximum effectiveness. A proprietary method for controlling the delivery of the helium to the chamber enables controlled rates of temperature change.

According to Robin Rhodes, President of Cryogenic Institute of New England, Inc., the capability grew from the needs of its aerospace customers who sought extreme temperature cycling for residual stress relief of critical components. “It was a natural extension for us to push beyond the limits of liquid nitrogen (77K/-196C/-320F), where we work every day, into the coldest cryogens available”, Rhodes stated. The company reported that they have delivered controlled cryogenic treatment profiles at temperatures ranging from 16K to 4K (-257C/-430F to -268C/-451F) over a dozen times in the past year. The temperatures and profiles were specified by the firm’s customers, who Rhodes declined to identify because of confidentiality agreements.

While the majority of applications have been related to aerospace, the firm has also offered the capability to researchers and other industries, including electronics. Cost for the treatment varies, depending on ramp and soak times, but Rhodes estimates that his firm can offer a near absolute zero treatment cycle (to 4K) for less than 30% of the cost of similar processing as offered through governmental and other research organizations. “We feel that we have a real price breakthrough that will lead to further commercialization of ultra deep cryogenic treatments for residual stress relief and other transformations in materials”, Mr. Rhodes stated.

The Cryogenic Institute of New England, Inc., located at 90 Ellsworth St. Worcester, MA, is dedicated to the commercial application of cryogenic technologies to serve the needs of industry, government and scientists. The firm offers a full range of cryogenic services, including conventional cryogenic treatment, heat & freeze thermal cycling, cryogenic deflashing & deburring services, shrink fitting services, and dry ice (CO2) blast cleaning. It also offers engineering services, cryogenic lab work in support of R & D, and custom equipment design for new and unique cryogenic applications. It is a corporate sustaining member of the Cryogenic Society of America. To learn more visit http://www.nitrofreeze.com/.