Case Study: Automating Rifle Bolt Etching for Black Oxide Coating

abrasive blast machine for black oxide preparationIndustry: Firearm Manufacturing

Process: Etching rifle bolts for black oxide coating or final finishing

Solution: TT-36 – Multi-Gun Batch Blast Indexing Turntable

Background:

A major firearm manufacturing company sought to improve its rifle bolt etching process for black oxide coating. The company was transitioning to a new cell-manufacturing center and needed a solution to enhance part consistency and production efficiency.

Challenge:

In their previous manual processing setup, the manufacturer faced significant issues:

  • Inconsistent Quality: The finish was not uniform across all parts, leading to variations in the black oxide coating.
  • Manual Handling: Operators were burdened with the repetitive task of manually blasting each part, which left little time for quality control.
  • Inefficiency: Each part required individual attention, limiting throughput and increasing cycle times.

The customer needed an automated abrasive blast solution that would address these challenges while improving overall efficiency and part finish quality.

Solution:

The firearm manufacturer selected our TT-36 Multi-Gun Batch Blast Indexing Turntable, a high-efficiency automated system designed to process up to 12 parts simultaneously. This equipment offered several key advantages:

  1. Improved Efficiency:
    • The batch process allowed operators to handle more parts at once, boosting productivity. While one set of parts was being blasted, the operator could inspect and package previously finished parts, eliminating the need for a separate inspection station.
  2. Superior Part Finish:
    • The system utilized two blasting stations with multiple fixed suction guns for improved coverage. This multi-gun approach ensured a uniform finish across all surfaces of the rifle bolts, addressing the inconsistencies experienced with the manual method.
  3. Enhanced Control:
    • The PLC controls and operator’s interface panel gave the operator precise control over the blasting cycle. With the flexibility to select 1 to 12 parts per cycle, the system blasted only the necessary number of parts, optimizing air usage and minimizing unnecessary component wear.
  4. Durability and Cleanliness:
    • The TT-36 included a range of features to maintain equipment cleanliness and protect wear-prone areas, such as:
      • Protective cabinet lining
      • Lined reclaimer
      • Covered turntable
      • Window covers and doorsills

These enhancements ensured the system remained in optimal condition, reducing maintenance needs and prolonging the lifespan of the equipment.

Results:

By integrating the TT-36 into their cell-manufacturing center, the customer achieved:

  • Consistent, High-Quality Finishes: The uniform blasting across all surfaces led to a superior black oxide coating, significantly improving product quality.
  • Increased Efficiency: The batch processing allowed the operator to multitask, reducing downtime and improving throughput.
  • Reduced Wear and Air Consumption: Precise part selection and advanced system controls minimized unnecessary air use and extended the life of the equipment components.

Conclusion:

The TT-36 Multi-Gun Batch Blast Indexing Turntable transformed the customer’s rifle bolt etching process, delivering superior quality and operational efficiency. This solution not only met the customer’s immediate production needs but also set them up for long-term success in their cell-manufacturing environment.