THE BASICS OF THE GIANT PROCESS

THE COMPONENTS
The Giant Finishing Machine is composed of a spiral-shaped bowl, mounted on coil springs
supported by a base. A system of revolving eccentric weights vibrates the tub.

THE METHOD
The tub is filled with media and the parts which need finishing are dispersed. A water diluted chemical
compound solution is injected to clean and prevent corrosion of metallic parts. Vibrating action
causes a smooth spiral roll of the media-parts mass around the tub.

The process is completed by raising the built-in gate, deflecting the media and parts onto the built-in
screen deck. The media drops through the screen back into the tub, while the parts pass over the
screen to their next operation or container to be located under discharge deck.

CAPABILITIES AND APPLICATIONS

When the user selects the best combination of equipment, equipment setting, media and compound,
this process deburrs, cleans, improves surfaces and/or dries the following: stamped, machined, cast,
forged, compacted and welded parts (ferrous and non-ferrous metals), ceramics, plastics, wood and
other materials or pieces with simple or exacting requirements from a few pieces to thousands per
hour.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
 THE MANUAL
The following sections of this manual describe the INSTALLATION, OPERATION, and
MAINTENANCE of the Giant Finishing Machines.

INSTALLATION INSTRUCTIONS FOR THE GB SERIES MACHINES

PRELIMINARY POSITIONING

CAUTION: You may remove the machine from the skid in order to simplify
the placement at the installation site, but do not unpack the equipment until it arrives
at the installation site.

1. Checking for Damage. Be sure to inspect the shipment for damage before signing the bill of
lading. If damage has occurred, write "DAMAGED IN SHIPMENT" on the bill of lading before signing
it.

2. In Plant Transporting. Transport the machine on the skid to the area where the machine will
be placed. If the pathway to that location is too narrow to move the skid through the plant easily, then
remove the machine from the skid in the shipping area and transport it (removed from the skid) to the
installation area. See caution note above .

3. Positioning the Machine. Remove the machine from the skid and place it in the area in
which it is to be installed. Shipping brackets connect the base to the tub. Remove them. Move the
base and the tub to the proper position, that is, so the front is positioned efficiently for your set up.

4. Positioning the Electrical Control Panel. Move the electrical panel to the installation
point. Again, if space limitations require, remove the panel from the skid before it is transported to the
installation area. (Do not unpack the equipment until it arrives at the installation
site.)

5. Removing Brackets. Remove the four spacer blocks between the base and the tub. They are
identified by tags to aid in their location and to call attention to them.

NOTE: THE MACHINE CANNOT BE RUN UNLESS THESE BRACKETS ARE

COMPLETELY REMOVED. Gently rock tub on base to be sure It is completely free.
This completes the preliminary positioning of your equipment. You are now ready to install or
assemble the electrical system and the water system.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
 GIANT AUTO COMPOUND SYSTEM
PACKAGE CONTAINS

 Product information sheet

 Supply tube with foot valve - 9 Ft.
 Flow - meter
 2 foot length tubing with check valve
 Metering tip kit
 5 foot length tubing (flow - meter to machine)
 Float with chain
 15 gallon polypropylene container with cover
 Giant Pump
 Check valve

AUTOMATIC LIQUID PRE-MIX COMPOUND DISPENSING

SYSTEM INSTALLATION AND MAINTENANCE

The automatic pre-mix compound dispensing system has been specifically manufactured to allow for
trouble free operation. Please use this equipment carefully and observe all warnings and cautions.

INSTALLATION:

1. Select metering tip (see next section) and screw tip into suction stub on adductor body.

2. Slide open end of suction tube over the suction stub.

3. Attach end of discharge tube with clamp and flooding ring to discharge barb on adductor.

4. Insert foot valve end of suction tube into concentrate container. Level of concentrate must be
below level of unit, or it continue to draw after it is turned off.

5. Adjust chain length to position float at the desired level of solution. To prevent foaming, be
certain that the solution level will be above the point of discharge.

6. Install min. 2 inch water hose between inlet swivel and water spigot (min. 25 PSI pressure
required).
7. You have now completed the installation of the solution system.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
 INSTALLING THE ELECTRICAL PANEL
Material or Special Equipment Needed (to be supplied by the customer):

 Connection between junction box and panel (Step 3)

 Electrical power cable (Step 5)

PROCEDURE

1. Open the electrical panel and remove the electrical drawings from the door pocket inside the
panel.

2. Review the drawings in detail before proceeding with the connection of the various electrical
leads of the installation.

3. Connect Panel with junction box. The individual wires within the cables are numbered.

4. Attach all individual wires labeled with numbers coming from the machine to the corresponding
numbers on the terminal strip.

NOTE: The machine will not operate unless all connections are made.
CAUTION!
Step 5 should not be started until installation procedures
above (Steps 1 through 4) are completed.

5. Install electrical power cable (supplied by customer) through the top of the electrical panel,
connecting it to the main disconnecting device in the panel.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
 CHECKING ROTATION OF MOTORS
The direction of the main drive motor rotation is indicated by an arrow on the top of the guard. It
should appear to turn clockwise, when you look down on it.

1. Turn on the machine; observe the direction of rotation. If it is counter-clockwise, against the
direction of the arrow, the rotation must be corrected.

2. Correct the direction, if necessary, by reversing any two of the three main electrical leads to
the motor labeled T1, T2, and T3.

3. If the motor rotates in the proper direction, and if the water line connections are tight, the
machine can be loaded with media for running.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
 ADJUSTING WEIGHTS ON GB MACHINES
PURPOSE: To establish the proper vibrating action to process your parts to the desired finish.

INTRODUCTION: The design of the Giant Machines permits simple, fast adjustments which
control the action of the contents: the media-parts mass.

Once you achieve the setting most efficient for your purpose, you can record the setting, and by
always using this setting, achieve consistent results thereafter. The operator does not normally need
to make adjustments in the middle of a given operation, but he may need to adjust the action when he
wishes to make the following changes or adaptations:

 To finish different parts

 To use another media
 To use another ratio of parts to media.

BACKGROUND:

An electric motor, mounted vertically, operates the Giant Machine. This motor powers a shaft which
carries eccentric weights through V belts, idler and pulleys. The shaft is located in the center tube of
the tub. The tub is mounted on heavy duty coil springs supported by a base.

THE VARIABLES: Adjustment involves only three variables:

 The mass or number of top weights

 The mass or number of bottom weights
 The relative position of the top weight to the bottom weight indicated by the position on the
index plate

THE VIBRATOR SHAFT & WEIGHTS

Line on the index plate indicates position of bottom fly-wheel

These variables can be confusing if you do not understand the function of the weights. Following is
an explanation of the function of the weights and their locations.

Bottom Fly-Wheel

Function: This weight controls the roll rate of the mass. The greater the weight on the bottom, the
faster and more vigorous the roll or turnover rate of the media and parts.

Location: This weight is reached by opening the door in the base of the machine.

Top Fly-Wheel

Function: The top weight controls the speed of travel of the media and parts mass around the tub.
The greater the weight, the faster the speed of the media and parts.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
Weight Segments of Top and Bottom Fly-Wheels

Function: The weight segments increase (or when removed, decrease) the movement of the mass,
that is the roll, feed and amplitude. The segments are placed on the master weight in a given
position.

WARNING: The Fly-Wheels have a maximum capacity. Each machine model is

designed with master weights that will hold only a given number of weights.

DO NOT EXCEED THIS NUMBER.

The results of using more than the maximum number of weight segments are:

 Reduced bearing life

 Uncontrolled or erratic vibration causing harm to the drive system and overall machine
 Variable process results
 Difficulty in controlling separation of parts from media
 Greater loss of media due to increased wear rate, increasing cost of operation
 VOIDING OF WARRANTY

WARNING: The ADDING of ALLOWED ADDITIONAL weights also may require the
replacing of the ORIGINAL weight holding bolts with LONGER VERSIONS to safely secure the
ALLOWED ADDITIONAL WEIGHTS !!!

ADJUSTING YOUR MACHINE TO

YOUR PROCESS REQUIREMENTS
You have already understood the function of top and bottom master weights and ascertained that the
drive shaft rotation is clockwise. You are now ready to make the final weight adjustments.

If parts have been test-run in the Giant Finishing Lab, the machine should be ready to process. If
your parts were not test-run in the Giant Lab, use the following steps to set up your machine:

Start the machine and apply the following principles from that point.

Increasing roll. Should you need more roll of the mass, add one or more weight segments to the
bottom master weight.

Increasing feed. Should you need more feed, then add one or more weight segments to the top
master weight. Normally, you will have one to three fewer plates at the top than at the bottom.

Adjusting the Feed by Advancing the Top Weight Assembly on the Index Plate

You can further increase the feed by advancing the top weight assembly to 100 deg. or higher. You
rarely will need to set the top master assembly as low as 60 deg. You will find that settings between
90 and 110 deg. will apply to various applications and processes including feed control for separation

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
of media and discharge of parts.

Decreasing/Increasing Speed. Should you need more or less speed, turn the handle of Vari-Drive
Base.

Variable Speed AC Drive

To provide for infinitely adjustable vibrations per minute. Speed range from 900-1150 VPM, by means
of a Variable Frequency Drive.
Refer to: AC DRIVE

Frequency variation is provided by means of a variable speed drive system and is infinitely
adjustable. The adjustment control is located in the Control Panel.

CAUTION: Do not turn the control wheel (knob) unless the machine is running. To
increase the number of vibrations per minute turn the knob clockwise. To decrease the number of
vibrations per minute turn the knob counterclockwise. The variable speed mechanism has been set
at the factory for 900-1150 vibrations per minute or RPM. (Speed varies with machine.)

NOTE: To keep warranty in effect be sure to contact Giant Finishing if higher or lower RPM is
desired.

MONITORING FACTORS THAT AFFECT THE END PRODUCT

There are three control practices that are important to process control in any vibratory machine.

 Maintaining a consistent ratio of parts to media.

 Controlling the level of the media.

Various media formulas have wear rates of X pounds per hour of use. For positive and consistent
results and control, the operator must add media before each 8-hour shift.

The amount of media added will vary, depending on the type of media used. Use the following scale
to judge loss of media.

MEDIA WEIGHT
Ceramic Media Fast cut, medium cut, hard or 80 to 100lbs per cu ft
slow cut Depending on formula
Plastic Media 57 to 65lbs per cu ft
Depending on formula
Aluminum Oxide Random shaped media 110 to 120lbs per cu ft
Natural Stone 100 to 110lbs per cu ft
Steel Media 275 to 350lbs per cu ft

Wear rate of steel media is not measurable; however, loss of media from poor housekeeping can
create a need to monitor the level.

Establish the wear rate of the media you use and add the amount needed routinely every eight hours.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
 CONTROLLING COMPOUND CONCENTRATION
WITH THE AUTO-COMPOUND SYSTEM

Function: The Auto Compound System, provided as optional equipment on all Giant Machines, is
designed to provide trouble free service by automatically metering liquid compound and water into a
vibratory finishing machine.

Advantages:
The system provides the following advantages:

 Excellent economy of material, thus cost control

 Requires minimum operator attention
 Eliminates the chances for human error which can occur when using manual measurement
techniques
 Prevents corrosion when a steel media is used

The precise measurement of compound solution is most critical in vibratory machines using steel
media, because of the potential for corrosion of the media. Corrosion is avoided by controlling the
concentration of the compound both during the start-up phase and during the operating phase of the
machine.

CAUTION:
Use of compounds other than Giant liquid compound voids the pump warranty!

Adjusting the Solution System:

Controlling Concentration: Concentration represents the amount of compound in a given amount

of water. It is normally measured in fluid ounces per gallon of water or in percent by volume.

These instructions will deal with concentration in fluid ounces of compound per gallon of water.

The Purpose of Compounds: Compounds are designed for several purposes, which include the
following:

 Preventing corrosion of parts

 Cleaning Lubricating
 Soil suspension
 Controlling foam
 Compensating for water hardness

Normal Concentration Ranges: Modern vibratory finishing compounds are normally used in
concentrations of 1 to 3 ounces per gallon.

Ranges for Heavy-Duty Cleaning: The operator will need higher concentrations of compound in
water when he desires more vigorous cleaning. He may require as much as 3 or 5 ounces per gallon
when the compound must emulsify large quantities of oily soil.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
CONTROLLING THE RATE OF WATER FLOW

The Water Flow Meter: A meter with an adjusting knob on the flow meter controls the rate of water
flow into the vibratory machine.

Several ranges of flow meters are available; the one provided is determined by the size of equipment.
The flow meters are calibrated directly in gallons per hour or gallons per minute, depending on the
capacity.

NOTE: For systems not equipped with direct reading flow meters, water flow can be
computed:

Gallons per hour = fluid ounces per 28 seconds,

OR

Gallons per hour = 10 milliliters per 9.5 seconds.

For example, if you collect a total of 40 fluid ounces in 28 seconds from each spray header, the flow
rate is 40 gallons per hour, or if you collect 400 milliliters in 9.5 seconds from each spray header, the
flow rate is 40 gallons per hour.

Lower flows are used when the process is essentially clean or when very small media is used which
prevents the ready flow through of the solution.

Higher flows are used when large amounts of soil must be washed out of the finishing machine and
sometimes at start-up in the morning.

PROVIDING A QUICKER, MORE EFFICIENT START-UP

Speeding up the machine's readiness for use by initially increasing the water flow to fill machine
quickly, while holding concentration of compound constant. During a normal vibratory process, the
compound concentration is normally in the 1 to 3 ounce per gallon range for most deburring and
burnishing applications. It is important in critical applications to maintain these concentrations
throughout the process. This is especially important during start-up in the mornings.

At start-up, the machine is completely drained. To speed up the vibratory machine into a productive
state, it is often desirable to use a much higher than normal flow rate of compound concentration of
compound be held as a constant. It is important during this period that the concentration of
compound be held as a constant.

PART VOLUME AND MACHINE CAPACITY

Scope: To aid the reader in calculating the proper ratio of media to parts and to determine how many
parts he may put into the machine at one time for processing.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
Calculating Part Volume

Use a ruler or take dimensions directly from a print.

Length (in.) X Width (in.) X Height (in.) = Part Volume (cu. in.)

To determine the number of parts per Cubic foot:

1728 (cu. in.) divide by part volume (cu. in) = Parts per Cubic Foot

Calculating Media-To-Parts Ratios

The reader must picture a part "floating" in the media. The amount of space surrounding each part,
well distributed in this mass, will govern the amount of part-on-part contact that could be
expected during the processing cycle. The more critical the surfaces and/or the softer the metal
involved, the more separation is required and the higher the media-to-part ratio required.

Media to Part Ratio by Volume Normal Commercial Application

0:1 No media, part-on-part. Used for beating off burrs. No media for
cutting.
1:1 Equal volumes of media and parts, forgings, sand castings, crude, very
rough surfaces.
2:1 More gentle, more separation, still severe part on part contact
3:1 About minimum for non-ferrous parts. Considerable part-on-part
contact. Fair to good for ferrous metals.
4:1 Probably "average" conditions for non-ferrous parts. Fair to good
surfaces. Good for ferrous metals.
5:1 Good for non ferrous metals. Minimal part on part contact
6:1 Very good for non ferrous parts. Common for pre-plate finishes.
8:1 For higher quality pre-plate finishes
10:1 to 15:1 Used for very irregular shaped parts.
No Contact No part on part contact. One part per machine compartment or part
fixture

Filling the Machine

For example a GB-10 at 2:1 Ratio, will hold approximately 3.3 cubic feet of parts when filling the
machine, keep the ratio of media to parts in mind. If the calculated part volume capacity of a GB-10 is
3.3 cubic feet of parts, and the media/parts ratio is 2:1, then the proper amount of media to load into
the machine is 2 X 3.3 cubic feet or 6.6 cubic feet.

CHANGING THE SCREENS ON YOUR GIANT MACHINES

Description of the Separation System

The standard separation system is simple. It consists of a deck with parallel sides rigidly bolted to the
tub. Because of its parallel straight sides, media and parts do not have to change directions, speed
263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
up and slow down, or get hung up. The screen extends beyond the outside of the tub to allow greater
length for separation.

Changing screens may be necessary when changing from one process to another. The screens can
be changed in minutes. You need not to remove the heavy deck.

To change the screen:

1. Remove the bolts and the hold-down bars
2. Lift out the screen
3. Replace hold-down bars and bolts

For media unloading, the operator can either replace the screen or cover the screen with solid
material such as plywood or a plastic sheet. About 70 to 80% of the media will walk out over this
deck, requiring the operator assistance only to help push the balance out of the tub. This quick, easy
procedure eliminate the need for resealing bottom outlets. It also permits storage of media in
containers such as 55 gallon drums which are available in the average manufacturing facility. Both
standard and auto separation systems are available.

LUBRICATION INSTRUCTIONS
FOR DRIVE SYSTEM
MOTORS ONLY ON BELT DRIVEN MACHINES

Lubrication in the bearings should be re-greased 40 hours of operation. Use four (4) to six (6)
shots of grease.
VIBRATOR BEARINGS

If automatic lubrication is ordered, a service air line with a maximum of 75 PSI is required. An air
filter and water separator must be provided before entering the lubrication system. The grease
system reservoir is equipped with a low level micro switch that will shut the entire system down
when grease level becomes low.

Manual Grease Lubrication : Machine is lubricated at factory.

Unit must be lubricated every 40 hours of normal operation without fail. Grease to be used
must be MOBIL Grease XHP-221. Amount of grease needed in 40 hour period minimum of 2
shots from grease gun.

CAUTION: Dust and grit must be removed from all pressure fittings before
adding new grease.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
 CONSERVATION OF TUB LINING
To prolong the life of the lining be sure to keep it reasonably clean of oils and greases. This is easily
done by using one of the cleaning compounds manufactured by Giant. Do not use any of the strong
solvents used in the degreasing industry.

Care should be taken when running large, heavy pointed parts, or large amounts of steel stampings
that are sharp and pointed. The above situations could shorten life of the lining.

Periodically measure the thickness of the tub lining by driving a small diameter pointed object through
the lining until it strikes the steel wrapper, hold your thumb nail on the pointed object and remove, this
will give you the approximate amount of remaining lining.

When the remaining lining becomes 1/4" thick or less, consult your Giant Representative about
ordering a replacement, newly lined tub.

Please note that maximum credit cannot be given for old tubs returned to Giant Finishing (prepaid)
with lining that is completely worn through.

REPLACEMENT OF NEWLY LINED TUB:

1) Order newly lined tub from Giant Finishing

2) When you receive the new tub, remove your old tub from the machine in the following manner:

(a) Remove the drive belt

(b) Remove flo-thru hose and drain hoses (remove grease lines)
(c) Lift old tub from the springs and turn over on a flat surface
(d) Remove the vibratory unit and super structure (during this down time be sure to
check bearings and bearing end play)
(e) Re-install the removed components into the new tub and replace onto the chassis
and springs
(f) Return the old tub for relining.

The vibratory unit, with reasonable care will give you more maintenance-free time than any other unit
of its type on the market.

Check periodically for end play and properly lubricate as directed, then years of
trouble-free running can be expected.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
TROUBLE SHOOTING

With power on control panel-vibratory motor will not start:

1) Check main fuses on disconnect switch. If blown, replace as necessary.

2) Check motor starter heaters.

FUNDAMENTALS OF MASS FINISHING

A typical mass-finishing operation has many elements. Each one must be evaluated to determine
what is best for your application as well as your wallet. Mass finishing can be used to clean, burnish
or color parts. Each application requires different media and compounds. Also, part shape, size and
fragility must be considered.

CLEANING. Oil and grease are removed from a part using a saponifying compound in
combination with a non-abrasive media. Fast-cutting media and a detergent compound will cut
through a layer of paint. A cutting or non-abrasive media in a chemically active compound removes
heat treat, scale, and rust from steel or oxides from copper and brass.

CUTTING is best performed using a fast-cutting media to remove coated abrasive belting lines,
mold irregularities, machining marks or discoloration from heat treating. Cutting produces a smooth
matte finish that is free of surface abnormalities. The surface also displays low reflectivity.

Mass finishing regulates the degree of surface profile on a part. It is measured in terms of the
average micro-inch distance from the surface=s peaks to its valleys. The degree of surface texture is
expressed as the root mean square (RMS) of these surface variations. A higher micro-finish
translates into a rougher surface and, conversely, a lower number equates to a smoother surface.

BURNISHING a part=s surface involves smoothing the surface peaks into valleys, producing a
highly reflective finish. The operation uses non-abrasive sintered bauxite or metal media and a
viscous lubricating compound. Media with abrasive content can be used if the compound is
especially viscous. Certain general concepts about burnishing include: 1) Dense media is preferred;
2) Smaller size media burnishes more effectively; 3) Media previously broken in and free of sharp
edges or corners is required; 4) Burnishing cannot be achieved if a part=s surface is ultra-smooth and
devoid of surface peaks and valleys.

COLORING is another phase of finishing that shows the degree of light reflectivity or light distortion
of a part’s surface. The operation exposes the ultimate color potential, polish or brightness of a
part=s surface.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
DEBURRING removes undesirable protrusions and sharp edges generated from previous
manufacturing operations. There are three types of deburring operations.

1. Light deburring removes small brittle burrs produced by preliminary grinding operations or flash
resulting from powdered metal moldings. Using a long-wearing media, these appendages are broken
free from the part and the exposed edges are smoothed.

2. Heavy burr removal uses a fast-cutting media to remove large, thick burrs caused by sawing,
milling, drilling or turning operations.

3. Radiusing rounds sharp edges or corners using cutting media ranging in composition from
average to high.

PARTS ANALYSIS. In addition to addressing the work objective, proper media selection requires
analysis of a parts hardness, ductility and configuration.

HARDNESS impacts heavily on the type of abrasive used. Aluminum oxide abrasive has sufficient
hardness to cut metals, alloy metals and plastics. Silicon carbide is choice for processing carbides
and ceramics. Hard materials are more brittle, so long-wearing, light abrasive media is best for
removing heavy burrs.

In radiusing hard materials, a small radius is produced quickly. Heavy radiuses are harder to
generate. When ultra-smooth surface finishes are required on hard material, roughing must be
performed initially in the soft state to ensure a minimum of cutting in the hardened state.

Hardened work pieces are much less likely to be damaged by impingement or contact with other parts
or media, therefore, larger media is used.

DUCTILITY. Ductile parts are more prone to burring during preliminary machining operations. Such
burrs are difficult to remove and fast cutting media is needed to remove them. Also, such parts are
subject to more damage during the mass-finishing process from part-on-part impingement.

PART CONFIGURATION. A part=s shape can impede or restrict normal media contact during a
mass-finishing operation. One must consider recessed areas and odd-shaped parts when selecting
media.

MAJOR MEDIA SELECTION CONSIDERATIONS. Media needs to be shaped so that there

is as much surface contact as possible between media and parts. This is critical where parts have
hard-to-reach areas.

For a square part, the most productive media shape is a flat configuration. Cone-shaped, cylindrical or
triangular media penetrates recesses in parts and does not lodge in them.

Cone-shaped media is the most versatile for work applications because it features a flat base, flaring
body and narrow or pointed nose. Most media manufacturers provide this shape in four basic sizes:
3/8 by 2 inch; 2 by 5/8 inch; 3/4 by 7/8 inch; and 1-1/8 by 1/4 inch.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
SIZE SELECTION. Media size impacts the degree of cut or finish. Large media removes more
metal because of the increased force it imposes. However, damage may result from impingement and
denting. Careful control helps avoid this.

Conversely, smaller media produces smoother finishes, resulting from the reduced cutting action.

MEDIA COMPOSITION is the most difficult finishing decision because of the variables involved.
The choice of abrasive type and grade is based on the work objectives, such as burnishing, light
deburring, general purpose, fast cutting. Popular media selections are as follows:

1. Aluminum oxide abrasive media. The ideal aluminum oxide mass-finishing abrasive is
dense and tough. Sintered bauxite has these attributes. Harder than steel, this ceramic media is used
to color hardened steel, other ferrous metals, exotic metals, brass and aluminum. A pre-formed
version enhances luster on stainless steel and exotic non-ferrous materials. Shape and closely
controlled sizing also eliminate lodging in recessed areas.

Fused aluminum oxide abrasive is a dense, solid structure with fine crystal size and carefully
controlled chemistry.

Pre-formed aluminum oxide media is a random-shaped, free and fast-cutting media provided in graded
sizes for applications from burr removal to final surface finishing.

2. Silicon carbide. Unlike aluminum oxide, silicon carbide does not impregnate soft ductile
metals. Therefore, this media is best for parts that will be welded or braised, for bearing surfaces and
parts that will be machined after deburring. It is more friable than aluminum oxide and fractures more
readily in contact with work pieces under heavy loads. Diamond, cubic boron nitride and boron
carbide are the only media abrasives harder and sharper than silicon carbide.

Silicone carbide is especially effective with non-ferrous metals such as brass, copper and aluminum,.
It is preferred for finishing hard, brittle parts like cemented carbides, ceramics, granite, marble, glass,
cast iron and low-tensile-strength, ductile nonferrous materials.

3. Ceramic media. Ceramic compositions are virtually all abrasive, hard and are more
abrasive than equivalent resin-bonded media. The combination of an ultra-tough surface area and
rigidity exposes a constant abrading surface and an aggressive cutting action.
Available in a number of compositions, ceramic media can be used in a variety of delicate or
aggressive applications, including burnishing, radiusing, polishing, rapid cut down, deflashing, and
deburring.

4. Resin-bonded media produces softer surface finishing action and provides a uniform finish.
The media is best for parts requiring more restricted edge and corner radiusing in lower densities than
ceramic media. The media smooths parts but does not impart a high luster.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
POST-FINISHING OPERATIONS. Post-finishing processes often determine the type of media
used. If the part will be plated, a smooth surface is mandatory. If aluminum oxide abrasive is used, a
fine grit is needed to avoid subsequent dull plating.

For parts destined for welding, brazing or soldering, silicon carbide is required. Parts undergoing
painting are processed with fast-cutting media to develop the rough, matte finish required for
adhesion.

THE ROLE OF COMPOUNDS in mass finishing is to keep parts and media clean. The
chemical compounds remove solids and grease and lubricate the media. They also reduce loading
and glazing.

Some compounds are used in two-stage processes. Stage one fosters the rate of cut initially and the
second stage enhances luster. An abrasive compound is applied in the first operation for maximum
metal or burr removal. Following a careful cleaning operation, a burnishing compound is used that
lubricates the media parts and promotes coloring.

Compounds also reduce corrosion, effectively protecting parts during the entire manufacturing
operation. Chemically active compounds remove rust and scale from parts.

In burnishing operations, non-abrasive media immersed in a viscous compound works well. Abrasive
media is acceptable in company with more viscous compounds. Water is used less with metal parts
because of rusting. Caustic compounds are used with steel parts without concern for rust. Caustics,
however, will attack aluminum.

Steel and iron can be run with compounds above PH7. Brass, copper and stainless clean well in
slightly acidic compounds. Since aluminum parts require a neutral compound, detergents are used
because they do not attack metal.

With the availability of many machine designs, along with improved media, descaling can be
accomplished by mechanical action alone, free from compounds.

PARTS PROCESSING EQUIPMENT. The extensive availability of mass-finishing equipment

provides for a broad selection. Choices of mass-finishing equipment run the gamut from basic
rotating and vibratory units to automated designs producing high-energy output.
Machines can be divided into five major categories: 1) Barrel tumblers; 2) Vibratory finishers; 3)
Centrifugal finishers; 4) Centrifugal disc finishers; and 5) Spindle machines. The size and operating
intensity are major considerations when selecting media.

Tumbling barrels use media with more abrasive content and less strength. High-intensity machines,
such as centrifugal types use media with less abrasive but require material with high-impact strength.
Vibratory finishers range in the center in intensity between tumbling and centrifugal. Radial bowls are
regarded as the most gentle vibratory type. Circular vibratory bowls are popular where frequent
media changes are not required. Flo-thru finishing machines are used when the time cycle is
between 5-30 minutes and volume is great. Rectangular tub type machines are used when parts are
big or volume is not as great to load and unload manually.

PARTS DRYING USING NATURAL MEDIA

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com
Using corncob to finish ferrous and non-ferrous stampings for automotive, medical/dental, luggage
and appliance manufacturers is very common. Parts exit a tumbler or vibratory finisher coated with a
soap and rust-inhibiting oil. Water must be quickly eliminated to avoid spotting. Residual
contaminants are isolated and the rust inhibitor is evenly re-deposited.

The corncob media acts like a sponge. It pulls contaminants away from the parts, evaporating the
water, and distributing the rust-inhibiting oil evenly over the surface. The soft susrface of the corncob
media cushions the parts against damage during processing.

The corncob media also has consistent particle sizing. If media particle size varies, it adheres in the
slots and threads, and accumulates in passageways. To complicate matters, all vegetable-based
media swells when it contacts water. Thus, it is important that particle size be consistent, as with
corncob media.

The corncob media is manufactured from commercial ear corn as well as hybrid varieties. Milling
equipment progressively separates the components by finding, air classifying and screening.
Particles are separated and sized through aspiration and screening.

Seven commercial grades (and a few proprietary grades) are available, with granules ranging in size
from 1/4-inch to a material similar to fine powder. Applications range from drying to grit blasting.
Often, corncob media is used as a blending media with other materials to add volume, extend service
life and reduce costs. Product life is estimated at 40 to 80 dryer hours, depending on the condition of
loads as they are received from stampers.

Whether the application is drying or blasting, the corncob media remains virtually dust free. It is also
all-natural and biodegradable; therefore it does not present an environmental problem. The waste
product is dry, so it is more manageable and less voluminous than wet waste generated by aqueous
washers and other systems used to perform the same task.

Using corncob media in a 150F dryer is less costly than processing without media because of the
hotter temperatures and longer cycles that are needed when no media is used.

It is also worth noting that there are three ways to prevent water spotting: deionized water, hand
buffing or corncob media. Of these, corncob media is the most cost-effective. Corncob media also
adds luster to the parts.

263 Richert Road  Wood Dale, Illinois 60191  Tel: (708) 343-6900  Fax: (708) 343-6920
www.giantfinishing.com