The Barrel Tumbler

Barrel tumblers have an action similar to that of a rock tumbling and skidding down the slope of a hill. The
barrel tumbler’s corners lift the load as the barrel rotates until it reaches a point where it slides down the
side of the barrel. The parts are abraded and deburred as they bump and scrape against the media and the
other parts.
The Vibratory Tumbler
Vibratory tumblers have an action that is similar to filing. The cutting media surrounds the parts. The
eccentric, rotating weight shakes the tub in a circular path during which the entire load is lifted up at an
angle and then dropped. As the load is falling (but not actually airborne) the tub returns to an upward
position, applying an upward and angular force that causes a shearing action where the parts and media
rub against each other.
Cutting Action
While the barrel tumbler is grinding at an applied force, the vibratory tumbler is moving faster than a free
fall. The barrel tumbler’s applied force is normally 5 to 10 times the vibratory tumbler’s free fall force. In
the barrel tumbler, the entire cutting action is restricted to the slide area or 20 to 30% of the total load. In
the vibratory tumbler, the entire load is being cut with each pulse, about 1800 times a minute, explaining
why the vibratory tumbler has such short cycle times compared to the barrel tumbler.
The parts in a vibratory finishing system are actually moving only about 1/16” in relation to each other. The
parts in a barrel finishing system move across the entire diameter of the barrel. These movements cause
large radii to form in a barrel tumbler, but relatively small radii to form in a vibratory tumbler. The
tumbling barrel can form a one-eighth radius on a part, while removing very little material from the flat
sections. The vibratory tumbler must be set for violent action with large blocky media to produce a sizable
radius, but due to its scrubbing action, it will remove an appreciable amount of material from the flats.
Generally speaking, vibratory finishing systems tend to produce a very smooth flat finish because it really
laps the parts. The vibratory tumbler will also cut inside a tube or cup shaped piece, deburring any spot the
stone can reach. Since the load is moving as a unit, very fragile parts are quite safe in a vibrator. There is
no tearing action or unequal forces that tend to bend and distort parts. The larger the parts or media are,
the faster the cutting action. However, the weight of either does not seem to have as much effect as size,
since plastic media, 50% lighter than ceramic media, can provide a good cut.
Barrel finishing systems produce a more uneven surface and generally round off corners before deburring
much material from surfaces. There are times when this is desirable. For brute stock removal, the barrel
tumbler excels. Foundry castings and parts with heavy radii are usually run in a barrel tumbler. The barrel
tumbler’s peening action can be used to work tougher parts and stress relief machined parts. Hardened
and polished steel shot is used extensively in a barrel tumbler for producing a quick luster on parts. While
this media may be used in a vibratory machine, the barrel tumbler yields a denser surface and more luster.
Speed and Amplitude
The speed and amplitude of vibration is variable on most machines. High speeds (1800 cycles per minute)
and small amplitudes are used for fine finishes or delicate parts. Large amplitudes are used for heavier
cutting, varying the speed according to the finish requirement. High speeds with large amplitudes can roll
burrs in and even peen metal into holes and mushroom edges. The circulation of parts is best at higher
speeds; therefore, heavy pieces are run best at higher speeds with moderate amplitudes of  1/8” to 3/32“.
Cost
Cost is one factor that may decide the choice in some cases. Vibratory systems, due to their massive
construction, are much more expensive pieces of equipment. Barrel tumbling systems wear out tumbling
media at half the pace of vibratory systems, but have to run longer to do the same job.
Media
The tendency is to use ceramic preformed media or plastic preformed media in a vibratory finishing
system. Ceramic tumbling media is made with abrasive filler, much as a grinding wheel is made. For plastic
tumbling media, plastic is mixed with abrasive and cast to shape. Ceramic media uses aluminum oxide as
filler and plastic media uses quartz or silica for cleaner results.
Randomly shaped media, either man-made or natural, are rarely used for precision work, because they
tend to jam in the holes and do not deburr into corners or recessed areas. When using ceramic media, care
should be taken to avoid glazing or loading of the surface. It is a good practice to run the media with an
abrasive grain occasionally to roughen the surface and clean the pores.
Plastic tumbling media is self-cleaning due to its relatively soft bond. Since adding an abrasive to plastic
media materially reduces its life, this media should only be used for mild cutting jobs that do not require
adding an abrasive to the run. Plastic tumbling media produces large amounts of foam and residue, making
 it unsuitable for use in an enclosed tumbling barrel. Plastic tumbling media is mainly used for fragile parts
or soft metals. Since this media is less than half the weight of stone or ceramic tumbling media, it is safer
to use in such cases.
Water
In both systems, water is added to the load to absorb soils and lubricate the media. To help the water keep
the parts clean, chemical compounds are added. An abrasive is sometimes added to enhance the cutting
and deburring ability of the tumbling media. Most people assume it is the abrasive that does the cutting,
and deburring, but this is not so. The abrasive is used mainly to keep the stone rough enough to do the
cutting and deburring.
Much of the finesse of using finishing equipment effectively can only be gained by actually working with
the equipment. It is important to keep careful records of each run to learn its effect and also to allow the
results to be duplicated later.
Thus, there is no easy answer to the question, “Which system is best?” We have found through many years
of experience that to arrive at the proper choice, the particular requirement of the job must be studied
and the characteristics of the performance of each system must be known.

To achieve an optimal finish, these tumblers produce a cutting action by shaking the tub at a high speed.
This causes the tumbling media and parts to scrub against each other, producing thorough and precise
abrasions to remove burrs. A shaft with rotating eccentric weights mounted on the tub produces this
effective shaking action.
Due to its high speed and short stroke, large bulky parts run easily through this system without damage.
Typically, parts with long wingspans and landing struts run routinely in these systems. As a result of its high
speed, small orbit action, the powerful movement yields little stress on the parts. Vibratory tumblers can
be fully automated for a flow-through, continuous operation, or used for a basic batch operation.
Vibratory tumbling systems are the most widely used finishing systems for continuous and batch parts
finishing. Its rolling action removes material from recesses, pockets, and bores on delicate parts, making it
ideal for almost any size and shape part. Our vibratory deburring media are suitable for deburring and
edge finishing brass, aluminum, copper, iron, and stainless steel workpieces such as machined parts,
injection molded parts, stamped parts, and die casted parts.
You can use our vibratory Finishing machines to do the following:
 Remove sharp edges
 Edge breaking
 Remove visible burrs
 Remove projections at a specific magnification
 Edge rounding
 Burnishing and polishing
In general, the vibratory finishing machine is the more popular option than barrel finishing for most mass
finishing applications. This is mainly because of the vibratory finishing process is more compatible with
automation, which can reduce labor costs and save time.
It’s also ideally the better option for finishing delicate or very large parts and is better-suited for tight-
tolerance projects. Additionally, vibratory deburring media tends to produce a smoother finish without
causing excess wear on the surface, which increases the durability and extends the lifespan of the part.
A vibratory Finishing Machine generates a force on the parts, causing parts and media to turn and grind
against each other deburring or polishing the parts. Vibratory Finishing Machines can be used for
deburring and other mass finishing applications such as polishing, cleaning, descaling, and surface
preparation. Vibratory Finishing Equipment configurations are commonly tubs, round bowls, or thru-feed
machines resulting in a deburring or burnishing process that is inefficient to do by hand.
Avoiding Vibratory Tumbling Damage
1. Choose the Appropriate Media
Media selection is a huge factor in reducing the risk of damage from vibratory tumbling . The lighter and
smaller the media used in tumbling, the softer its touch and the less likely that media is to cause
unwanted dents, damage, or surface roughness.
There are three main groups of tumbling medias: plastics, ceramics, and hardwoods. Plastics are often
the best choice for those concerned about the risk for damage, because plastic medias result in the
smoothest finished surfaces when used in a vibratory tumbler. Plastics are lightweight (30% lighter than
ceramic tumbling media, in fact), so their impact against parts in a tumbler is more minimal. Plastics are
a great choice for products made of softer metals like brass or aluminum.
Ceramic finishing media is a dense, heavy media option that’s best suited for hard metals or products
that need areas to be worn down. In other words, it’s often not the best choice for delicate products.
Hardwood media is the lightest option that, when used in smaller pieces, is well-suited for parts of light
durability or very mild abrasiveness is required.
2. Choose the Right Media-to-Part Ratio
Delicate parts call for a higher media-to-part ratio in a vibratory tumbling system. Applying a little
napkin physics knowledge, we know that the less space something has to travel, the less force it has to
apply upon impact. The more media there is in a vibratory tumbler, the less space it has to hit up against
parts. Generally, a 3 to 1 ratio (by volume) of media to parts is good for deburring or deflashing. A 4 to 1
ratio or higher is better for burnishing an polishing.
3. Fast Speeds, Low Amplitude
In addition to selecting the right media-to-part ratio, be intentional about the speed at which you set
your vibratory tumbling system. Despite what you might think, parts that are fragile should actually run
at faster speeds. Faster speed settings in combination with low amplitude settings minimize the part’s
risk for high media impact. Again, the same physics logic from earlier applies here: there’s less space for
media to hit against a part’s surface, thereby lessening impact

A centrifugal barrel parts tumbler can eliminate 95% of the handwork involved in deburring or polishing parts
by hand. This reduction of hand sorting dramatically increases production and return on investment. Using a
centrifugal barrel finisher reduces the waste and expense of having to use a microscope to identify defects and
remove burrs on each part to meet a customer’s requirement for metal smoothness.
In addition, using a centrifugal barrel finishing machine increases consistency in quality. Handwork at best
yields an 80% acceptance rate, but with a centrifugal barrel finisher you can achieve much higher rates of
acceptance. In addition, the surface finish after centrifugal part tumbling is isotropic and consistent in all
directions, unlike hand polishing.
Use of a deburring machine also contributes to worker safety, since it reduces the risk of repetitive motion
injury such as carpal tunnel syndrome associated with deburring and polishing by hand. The centrifugal barrel
machine is far more ergonomic than handwork. While centrifugal tumblers do require operators to load each
barrel manually, the high speed of the machine makes up for this labor intensity.

What industries can benefit from High Energy Centrifugal Barrel and Harperizing Metal Finishing Machines?
The centrifugal barrel finishing machine is a versatile tool that is used in a wide variety of industries for metal
finishing.
 Medical Device: Medical device customers expect consistent, high-quality finishes on metal parts, often
with complex geometry. Centrifugal barrel finishing delivers fast performance for polishing and/or
deburring of stainless steel, titanium and cobalt chrome implantable and surgical parts. Other
applications that benefit from centrifugal barrel finishing include dental implants and dental tool
polishing.
See also the case study on mass finishing and deburring of medical device surgical parts.
  Aerospace and Defense: Metal smoothness is often a crucial requirement for high-performance
aerospace parts. Deburring aerospace parts by hand is not cost-effective, so manufacturers use
centrifugal barrel finishers for this task. Examples of parts that benefit from this process include jet
engine and turbine blades.
 Automotive: The automotive industry benefits from centrifugal barrel finishing machines for smoothing
the surface of metal parts. In particular, the automotive industry uses centrifugal parts tumblers to
polish engine heads, gears and fasteners.
 General Job Shop: At general machine shops, centrifugal barrel finishers provide fast, cost-effective
performance for polishing and deburring metal parts.
Small Centrifugal Barrel Tumbling Machine

How to use an Industrial Parts Tumbler

The type of work that an industrial tumbler machine performs can be placed into three categories, in
ascending order of smoothness:
1. Deburring. Deburring is the process of removing sharp edges, or burrs, from a metal surface that are
left after machining. A common example of deburring is to smooth a sharp corner into a rounded
corner in a piece of metal.
2. Blending machining lines. Similar to deburring, blending smooths the finish on a piece of metal.
Blending removes the machine lines left in the process of milling and cutting metal to the correct size
and shape.
3. Polishing. The polishing process, also called burnishing, takes the part to the next level of smoothness.
Polished parts are made shiny and can achieve a mirrored look.
Centrifugal barrel finishing machines can perform each of these three types of work, also called steps.
Depending on surface finishing specifications for your product, not all steps may be necessary. Your process
might include a single step, two steps, or three steps.
Regardless of the number of steps in your process, each step must be performed separately. In other words,
you cannot perform deburring and polishing simultaneously. Instead, deburr first, then polish. If more than
one step is required, the steps must be performed in ascending order of smoothness, with deburring first and
polishing last.
Video: 2-Step Process Demo of Centrifugal Barrel Finishing Machine

Wet or Dry Processing with a Centrifugal Barrel Tumbler Machine

Mass finishing with a centrifugal barrel tumbler can be performed either wet or dry. Wet processes use a liquid
lubricant, cleaner or abrasive, and dry processes do not. Each of the four barrels is loaded to roughly 50-80% of
capacity with the following elements:
For wet processing:
1. Metal parts (the workpieces)
2. Abrasive media
3. Water
4. Cleaning compound (detergent)
For dry processing:
1. Metal parts (the workpieces)
2. Abrasive media, may include dry compound
The polishing step is usually a dry process using ground-up corn cob as media, with polishing compound
embedded. Ground-up walnut shells are also used as media for dry processing.
What abrasives are used as tumbler media?
Tumbler media is the abrasive used in mass finishing that grinds away the burrs and cutting lines on a metal
surface. Tumbler media comes in many shapes and forms.
With the many options available, there is a certain art to selecting the correct media. Using incorrect media
can cause significant problems, such as media becoming stuck in a hole in the part or damaging the part.
As a general rule, the darker the media, the faster it cuts. For example, if plastic media is very dark, it’s likely to
be fast-cutting with a more aggressive abrasive. Lighter-colored media is more likely to be mild cutting for
mildly abrasive mass finishing.
How to get the best results with an industrial tumbler machine

Best practices in centrifugal parts tumbling include the following:

  Avoid long cycle times. Be aware that centrifugal barrel tumbling generates a significant amount of
heat within each barrel. For example, at 150 rpm a 120-liter centrifugal barrel machine will boil water
in 15-20 minutes. Operators need to keep the heat level in mind for safety reasons as well as how it
impacts the surface finishing process. Because of the heat generated, very long cycle times are not
desirable. Typical cycle times are 5-15 minutes for most parts. Over an hour would be considered a long
cycle and not recommended.

 Avoid overloading. Putting too many parts in the barrels will result in part-on-part contact that can
damage the parts. For cosmetically-sensitive parts, this can be addressed with the use of barrel
dividers. Other important factors include the part-to-media ratio in each barrel, and using an
appropriate amount of water and cleaning compound.

 Balance the machine. A typical centrifugal barrel finishing machine contains 4 barrels. Avoid filling just
one barrel on a cycle, as this practice is hard on the bearings and can cause the machine to “walk.” If
you do have to use an odd number of barrels, then counter-balance the barrel opposite it. If nothing
else, fill the opposite barrel with water to help counter-balance the machine.

 Communicate. Often a part removed halfway through its expected cycle time will meet a customer’s
needs. The time savings in production can be well worth the investment in testing and providing
samples for the customer.

Tips for better centrifugal barrel finishing

Don’t forget the detergent. You might think that cleaning compound was intended for the metal parts, but in
fact the tumbling media needs it. Cleaning compound adds lubricity to keep the pores open in the tumbling
media. Once the pores in tumbling media become glazed over, the cutting action of the tumbling media will no
longer work and metal parts turn out black. If the parts come out black, you forgot to put in the soap.

Flummoxed by flat parts? Flat parts such as washers present one of the toughest challenges for centrifugal
barrel finishing. The parts tend to wick together or stick to the side of the barrel, so only one side gets
deburred. The solution is to add glass bead blasting media to the centrifugal barrel finishing process. The beads
coat the parts so they can no longer stick to the barrel or each other. Glass beads also work well for parts that
tend to cup together.

Want a matte or satin finish? Add aluminum oxide blasting media to your centrifugal barrel finishing process,
and the resulting part will be matte instead of shiny.

Reduce the mess. The sludge that builds up in the sludge tank needs to be cleaned out regularly. Here’s a tip
to reduce the mess. After draining the water, put horse bedding in the sludge tank to absorb the remaining
water. This technique makes it much easier and less drippy to remove the sludge with a shovel.