Small Lab Manual Shot Blasting Machine
The Small Lab Manual Shot Blasting Machine is a specialized surface treatment equipment designed for laboratory-scale research, small-batch sample processing, and educational purposes. Unlike large-scale industrial shot blasting machines that prioritize high efficiency and mass production, this compact and manually operated device focuses on precision, flexibility, and ease of use, making it an indispensable tool in material science laboratories, university research centers, and small manufacturing workshops that require customized surface treatment of small workpieces. This manual aims to provide a comprehensive overview of the Small Lab Manual Shot Blasting Machine, including its structural composition, working principle, performance characteristics, application scenarios, operation procedures, maintenance guidelines, and safety precautions, to help users fully understand and properly use the equipment.
Structural Composition
The Small Lab Manual Shot Blasting Machine consists of several core components that work together to achieve the shot blasting process. Each component is designed with compactness and operability in mind, ensuring that the equipment can be easily placed in a laboratory environment and operated by a single user. The main structural components include the blasting chamber, manual operation system, abrasive storage and feeding system, dust removal system, and workpiece clamping device.
The blasting chamber is the core working area of the machine, where the abrasive particles impact the workpiece surface. It is usually made of high-strength steel plates with a thickness of 3-5mm to withstand the impact of abrasive particles. The inner wall of the chamber is often lined with wear-resistant rubber or polyurethane plates to reduce wear and extend the service life of the chamber. The size of the blasting chamber varies according to the model, generally ranging from 500mm×400mm×300mm to 800mm×600mm×500mm, which can accommodate small workpieces with a maximum size of 300mm×200mm×200mm. The front of the chamber is equipped with a transparent observation window made of high-strength tempered glass, allowing users to observe the shot blasting process in real time. The chamber door is designed with a manual locking mechanism to ensure that the door is tightly sealed during operation, preventing abrasive particles from splashing out.
The manual operation system is the key part that distinguishes this machine from automatic or semi-automatic shot blasting equipment. It includes a manual abrasive control valve, a workpiece rotation handle, and a blasting nozzle adjustment mechanism. The manual abrasive control valve is used to regulate the flow rate of abrasive particles, which can be adjusted according to the surface treatment requirements of the workpiece. The flow rate range is usually 0.5-5kg/min. The workpiece rotation handle allows users to manually rotate the workpiece during the shot blasting process, ensuring that all surfaces of the workpiece are evenly blasted. The blasting nozzle adjustment mechanism enables the user to adjust the angle and position of the nozzle, which can be rotated 360 degrees and adjusted up and down within a certain range to meet the shot blasting needs of workpieces with different shapes and sizes.
The abrasive storage and feeding system is responsible for storing and supplying abrasive particles to the blasting nozzle. It consists of a storage hopper, a feeding pipe, and a manual feeding device. The storage hopper has a capacity of 10-20kg, which is sufficient for laboratory-scale operation. The feeding pipe is made of wear-resistant steel pipe to prevent blockage and wear caused by the flow of abrasive particles. The manual feeding device allows users to manually add abrasive particles to the storage hopper, which is simple and convenient to operate. Common abrasive particles used in small lab manual shot blasting machines include steel shots, steel grits, aluminum oxide, and silicon carbide, with particle sizes ranging from 0.1mm to 1.0mm. Users can choose the appropriate abrasive according to the material and surface treatment requirements of the workpiece.
The dust removal system is an important component to ensure the laboratory environment is clean and safe. Since the shot blasting process will generate a large amount of dust, which contains abrasive particles and workpiece surface debris, the dust removal system is used to collect and filter these dusts. The small lab manual shot blasting machine usually adopts a bag-type dust remover or a cyclone dust remover. The bag-type dust remover has a high dust removal efficiency, which can reach more than 99%, and is suitable for collecting fine dust. The cyclone dust remover has a simple structure and low cost, and is suitable for collecting large-particle dust. The dust removal system is connected to the blasting chamber through a dust suction pipe, and the dust generated during the shot blasting process is sucked into the dust remover for filtration. The filtered clean air is discharged into the laboratory, and the collected dust is stored in a dust collection box, which can be cleaned regularly.
The workpiece clamping device is used to fix the workpiece in the blasting chamber to prevent the workpiece from moving during the shot blasting process. It includes a clamping fixture and an adjustment mechanism. The clamping fixture can be replaced according to the shape and size of the workpiece, such as flat fixtures for flat workpieces, cylindrical fixtures for cylindrical workpieces, and custom fixtures for special-shaped workpieces. The adjustment mechanism allows users to adjust the position and angle of the clamping fixture to ensure that the workpiece is in the optimal shot blasting position.
Working Principle
The working principle of the Small Lab Manual Shot Blasting Machine is based on the principle of mechanical impact. By accelerating abrasive particles to a certain speed and making them impact the surface of the workpiece, the surface impurities (such as rust, oil stains, oxides, and burrs) are removed, and the surface of the workpiece is roughened, thereby improving the surface quality and adhesion of the workpiece. The specific working process can be divided into the following steps:
First, the user checks the equipment to ensure that all components are in good condition, the abrasive particles in the storage hopper are sufficient, and the dust removal system is working normally. Then, the workpiece to be processed is fixed on the clamping fixture in the blasting chamber, and the chamber door is closed and locked.
Next, the user turns on the power switch of the machine, and adjusts the manual abrasive control valve to set the appropriate abrasive flow rate. Then, the user holds the blasting nozzle adjustment mechanism, adjusts the angle and position of the nozzle to align with the surface of the workpiece, and starts the shot blasting process. During the process, the user can rotate the workpiece rotation handle to make the workpiece rotate, ensuring that all surfaces of the workpiece are evenly impacted by the abrasive particles. The user can observe the shot blasting effect through the transparent observation window and adjust the nozzle angle, flow rate and other parameters in real time according to the effect.
In the shot blasting process, the abrasive particles in the storage hopper enter the blasting nozzle through the feeding pipe under the action of gravity or a small air pump. The blasting nozzle accelerates the abrasive particles to a speed of 30-80m/s by means of compressed air or centrifugal force. The accelerated abrasive particles are sprayed onto the surface of the workpiece, and the impact force generated by the collision removes the impurities on the surface of the workpiece. At the same time, the surface of the workpiece is roughened, forming a uniform matte surface or a specific roughness surface.
The dust generated during the shot blasting process is sucked into the dust remover through the dust suction pipe. The dust remover filters the dust, the filtered clean air is discharged, and the dust is collected in the dust collection box. After the shot blasting is completed, the user turns off the power switch, opens the chamber door, takes out the processed workpiece, and cleans the blasting chamber and dust collection box.
Performance Characteristics
The Small Lab Manual Shot Blasting Machine has a series of performance characteristics that make it suitable for laboratory-scale use. First of all, it has the advantage of compact structure and small size. The overall dimensions of the machine are usually 1000mm×800mm×1200mm to 1500mm×1000mm×1500mm, which occupies a small area and can be easily placed in a laboratory or small workshop. It is light in weight, generally 50-150kg, and can be moved easily if necessary.
Secondly, it has high flexibility and adjustability. The manual operation system allows users to adjust various parameters according to the specific requirements of the workpiece, such as abrasive flow rate, nozzle angle, and workpiece rotation speed. This flexibility makes the machine suitable for processing workpieces of different materials (such as metal, plastic, ceramic, etc.), different shapes (such as flat, cylindrical, special-shaped, etc.), and different surface treatment requirements (such as rust removal, deburring, roughening, etc.). Users can carry out customized surface treatment according to the needs of the experiment or production, which is difficult to achieve with large-scale automatic equipment.
Thirdly, it is easy to operate and maintain. The machine has a simple structure and a user-friendly operation interface. Even users without professional operation experience can master the operation method through simple training. The maintenance work is also relatively simple, mainly including regular cleaning of the blasting chamber and dust collection box, checking the wear of the nozzle and feeding pipe, and adding abrasive particles. The maintenance cost is low, which is suitable for the budget constraints of laboratories and small workshops.
Fourthly, it has good safety and environmental protection performance. The machine is equipped with a complete safety protection device, such as a chamber door interlock device (which can ensure that the machine cannot be started when the chamber door is open), a transparent observation window with protective film, and a dust removal system. These devices can effectively prevent abrasive particles from splashing and dust pollution, ensuring the safety of operators and the cleanliness of the working environment.
Finally, it has stable performance and high processing quality. The machine adopts high-quality components, such as wear-resistant nozzles, high-strength clamping fixtures, and efficient dust removers, which ensure the stability of the machine during operation. The manual operation allows users to accurately control the shot blasting process, ensuring that the surface of the processed workpiece has uniform roughness and good surface quality. The processing accuracy can reach Ra 0.8-6.3μm, which can meet the requirements of most laboratory experiments and small-batch production.
Application Scenarios
The Small Lab Manual Shot Blasting Machine is widely used in various fields that require laboratory-scale surface treatment. Its main application scenarios include material science research, university education and teaching, small-batch sample processing, and surface treatment of precision components.
In the field of material science research, the machine is used to study the influence of surface treatment on the performance of materials. For example, researchers can use the machine to roughen the surface of metal materials and then study the effect of surface roughness on the corrosion resistance, fatigue strength, and adhesion of coatings of the materials. It can also be used to study the surface modification of new materials, such as ceramic materials and composite materials, to improve their surface performance. The flexibility and adjustability of the machine allow researchers to carry out a variety of experiments and obtain accurate experimental data.
In university education and teaching, the machine is used as a teaching tool to demonstrate the principle and process of shot blasting surface treatment. Students can observe the shot blasting process through the transparent observation window, understand the working principle of the equipment, and master the operation method of the machine. It can also be used for students' experimental courses, allowing students to carry out practical operations, such as processing small workpieces, measuring surface roughness, and analyzing the influence of different process parameters on the processing effect. This helps to improve students' practical ability and understanding of professional knowledge.
In small-batch sample processing, the machine is used by small manufacturing workshops, research and development centers, and other units to process small batches of samples or prototypes. For example, in the automotive parts industry, it can be used to process small batches of auto parts samples to test their performance; in the electronic product industry, it can be used to remove burrs on the surface of electronic components to improve their quality and reliability. The small size and low cost of the machine make it suitable for small-batch production, avoiding the high cost of using large-scale industrial equipment.
In the surface treatment of precision components, the machine is used to process precision components that require high surface quality, such as precision bearings, gears, and molds. The manual operation allows users to accurately control the shot blasting process, avoiding excessive impact on the surface of the precision components and ensuring their dimensional accuracy and surface quality. For example, it can be used to remove the oxide layer on the surface of precision bearings without damaging the raceway of the bearings, thereby improving the service life of the bearings.
Operation Procedures
The correct operation procedure is crucial to ensure the normal operation of the Small Lab Manual Shot Blasting Machine, improve the processing quality, and ensure the safety of operators. The specific operation procedures are as follows:
1. Pre-operation inspection: Before starting the machine, the user must conduct a comprehensive inspection of the equipment. Check whether the power supply is connected correctly, whether the wires are damaged; check whether the abrasive particles in the storage hopper are sufficient, and whether the type and particle size of the abrasive are consistent with the processing requirements; check whether the blasting chamber is clean, whether there are residual abrasive particles or debris; check whether the clamping fixture is intact, whether it can firmly fix the workpiece; check whether the dust removal system is working normally, whether the dust suction pipe is unblocked; check whether the chamber door is tightly sealed, and whether the interlock device is working normally.
2. Workpiece installation: Place the workpiece to be processed on the clamping fixture in the blasting chamber. Adjust the position and angle of the clamping fixture to ensure that the workpiece is firmly fixed and the surface to be processed is facing the nozzle. Close the chamber door and lock it tightly to ensure that the door is sealed.
3. Parameter setting: Turn on the power switch of the machine. Adjust the manual abrasive control valve to set the appropriate abrasive flow rate according to the processing requirements of the workpiece. Generally, the flow rate for light rust removal or deburring is 0.5-2kg/min, and the flow rate for heavy rust removal or roughening is 2-5kg/min. Adjust the angle and position of the nozzle to align with the surface of the workpiece.
4. Start the dust removal system: Turn on the switch of the dust removal system to ensure that it is working normally before starting the shot blasting process. This can effectively collect the dust generated during the shot blasting process and protect the working environment.
5. Shot blasting operation: Hold the blasting nozzle adjustment mechanism, and start the shot blasting process by opening the manual control valve. During the operation, observe the shot blasting effect through the transparent observation window. Rotate the workpiece rotation handle to make the workpiece rotate, ensuring that all surfaces of the workpiece are evenly blasted. Adjust the nozzle angle and flow rate in real time according to the shot blasting effect to ensure that the processing quality meets the requirements.
6. Stop the machine: After the shot blasting is completed, first close the manual abrasive control valve to stop the supply of abrasive particles. Then, continue to run the dust removal system for 2-3 minutes to collect the remaining dust in the blasting chamber. Turn off the power switch of the machine and the dust removal system.
7. Workpiece removal and equipment cleaning: Open the chamber door, take out the processed workpiece, and check whether the surface quality meets the requirements. If not, reprocess it according to the above steps. Clean the blasting chamber, remove the residual abrasive particles and debris, and clean the dust collection box of the dust remover. Check the wear of the nozzle and feeding pipe, and replace them if necessary. Add abrasive particles to the storage hopper for the next use.
Maintenance Guidelines
Regular maintenance of the Small Lab Manual Shot Blasting Machine can extend the service life of the equipment, ensure its stable performance, and improve the processing quality. The maintenance work mainly includes daily maintenance, weekly maintenance, monthly maintenance, and annual maintenance.
Daily maintenance: After each use of the machine, clean the blasting chamber, remove the residual abrasive particles and debris. Clean the dust collection box of the dust remover, and dispose of the collected dust properly. Check the wear of the nozzle; if the nozzle is worn seriously (the inner diameter increases by more than 10%), replace it in time. Check the tightness of the chamber door seal; if the seal is loose or damaged, adjust or replace it. Check the abrasive particles in the storage hopper, and add them if necessary. Turn off the power supply and keep the equipment clean and dry.
Weekly maintenance: Check the feeding pipe for blockage or wear; if there is blockage, clean it in time; if there is wear, replace it. Check the clamping fixture for deformation or damage; if so, repair or replace it. Check the dust suction pipe for air leakage or blockage; if there is air leakage, seal it with sealant; if there is blockage, clean it. Check the lubrication of the workpiece rotation mechanism; add lubricating oil if necessary. Check the power cord and plug for damage; if so, replace them in time.
Monthly maintenance: Check the inner wall lining of the blasting chamber for wear; if the lining is worn through or falls off, replace it. Check the dust remover filter bag (for bag-type dust remover) or cyclone cone (for cyclone dust remover) for wear or blockage; if the filter bag is clogged, clean it; if it is worn, replace it. Check the manual abrasive control valve for flexibility; if it is stuck, disassemble and clean it. Check the overall structure of the machine for loose screws or bolts; tighten them if necessary.
Annual maintenance: Conduct a comprehensive inspection of the machine, including the motor (if any), air pump (if any), and other components. Check the insulation performance of the power supply; if the insulation is poor, repair it. Disassemble the key components of the machine, such as the blasting nozzle, feeding pipe, and clamping fixture, and clean and inspect them thoroughly. Replace the worn components in a unified manner. Calibrate the parameters of the machine, such as the abrasive flow rate, to ensure its accuracy. After the maintenance is completed, conduct a test run to ensure that the machine is working normally.
Safety Precautions
When using the Small Lab Manual Shot Blasting Machine, operators must strictly abide by the safety precautions to avoid accidents such as personal injury and equipment damage. The specific safety precautions are as follows:
1. Operators must receive professional training before operating the machine, be familiar with the structure, working principle, and operation procedures of the machine, and pass the assessment before taking up the post. It is strictly forbidden for untrained personnel to operate the machine without authorization.
2. Operators must wear personal protective equipment during operation, including safety glasses, dust masks, protective gloves, and protective clothing. Safety glasses can prevent abrasive particles from splashing into the eyes; dust masks can prevent inhalation of dust; protective gloves and clothing can prevent abrasion of hands and body.
3. It is strictly forbidden to open the chamber door during the shot blasting process. The chamber door interlock device must be kept in good condition; it is strictly forbidden to tamper with or disable the interlock device. If the chamber door needs to be opened during the operation due to special circumstances, the power supply must be turned off first, and the door can be opened only after the machine stops completely.
4. It is strictly forbidden to put hands or other parts of the body into the blasting chamber during the operation to avoid being hit by abrasive particles.
5. The working environment must be well-ventilated. Although the machine is equipped with a dust removal system, it is still necessary to ensure that the laboratory has good ventilation conditions to further reduce the concentration of dust in the air.
6. It is strictly forbidden to use flammable, explosive, or toxic abrasive particles. The abrasive particles used must be dry and free of impurities to avoid blockage of the feeding pipe and affect the normal operation of the machine.
7. When adding abrasive particles, the power supply must be turned off first to avoid accidents caused by the sudden start of the machine. The added abrasive particles should not exceed the maximum capacity of the storage hopper to avoid overflow.
8. If the machine fails during operation, the power supply must be turned off immediately, and the fault should be checked and eliminated after the machine stops completely. It is strictly forbidden to repair the machine while it is running.
9. After the operation, the power supply must be turned off, and the equipment and the working environment must be cleaned. The dust collected in the dust collection box must be disposed of in accordance with environmental protection requirements, and it is strictly forbidden to dump it randomly.
10. The machine must be used within the rated parameters, and it is strictly forbidden to overload or overuse it for a long time, so as to avoid damage to the equipment.
