Resin bond abrasive disc is a kind of grinding wheel, which is the most important special grinding tool in the grinding process. Performing a perfect job is the goal of every professional.The abrasive discs are a fundamental piece to be able to use a fixed or portable tool that helps us to cut, roughing or sanding any material, through friction. Its design, shape and composition will vary according to the use that will be given. There are many different raw materials for abrasive disc.Resin bond abrasive disc has high toughness and certain ductility,The use of abrasive disc in the secondary steel industry is widespread: from shipbuilding and manufacturing of household appliances, components for the automotive and construction sectors, special profiles, pipes and electrical appliances to maintenance and repair of equipment, tools and machines. An unpolished finish, with a polished surface, well treated and with all the necessary tools, are fundamental requirements for this. But, to achieve this, it is necessary to know what the elements with which we can work are and know how to differentiate which is better for each occasion.The performance of abrasive disc is very different, which has a significant impact on the production quality, production efficiency and rationality of grinding.
We want to help you in everything within our reach, providing you with all the products you need and with the highest quality guarantee. In addition, we accompany you throughout the process, guiding and advising you on what is best for each of your projects. Therefore, this time we will explain everything about abrasive discs: what they are, the different types, their characteristics.
The manufacture of resin bond abrasive disc is also very important. The key to mixing resin bond abrasive disc is to mix resin, fillers, additives and steel grit evenly. The forming glue should meet the following requirements: the components are distributed jointly, adhered to the surface of the wear-resistant material, and maintained loose. However, there should be no significant powder leakage, and it is necessary to ensure that the pavement is symmetrical and the forming characteristics are good. In order to better make the resin completely adsorbed on the surface of the wear-resistant material, the material must be mixed and stand for 24 hours.
During the 24 hours , maintain the temperature at 20-30°C, the humidity at 40-50°C, and leave the materials stay for over 24 hours to ensure the forming reliability of the abrasive disc.
The resin bond abrasive disc processing technology is the main production process, and there are two factors that easily cause quality problems. First, the temperature difference between the curing oven and the continuous oven is too large; second, the putting material method is unreasonable.
The semi-finished product is soft, and dries up according to the chemical change of the resin heated at high temperature. Different size abrasive disc have different hardening temperatures. The higher the resin composition, the higher the hardening temperature.So, let’s take a look at the key components of the abrasive disc .
The abrasive disc is composed of three parts: abrasive, binder (fusion agent), and pores.
1.Abrasive: It is the key working part of the abrasive disc . It has sharp edges and corners, that is, a small cutting edge. It is used to turn and produce work piece. In general, its composition is based on a series of crushed abrasive grains, joined together by a binding agent, anchored and fixed to a support material. These grains can be made of natural or synthetic aluminum oxide, silicon carbide, zirconium, ceramic or diamond.The most common are the diamond saw blade and the abrasive disc.According to the material of which the disc is made we can find two categories;The conventional ones: that come from aluminum oxide, silicon carbide or a mixture of aluminum oxide and zirconium. They are ideal for working with soft, hard and semi-hard materials. They are used to cut, rough and polish steel, cast iron, ceramics, copper.The super-abrasive: in this block the abrasive discs that have to carry out a more intense cut are included. They are used exclusively for cutting and roughing at high speed, and in a very precise way, very hard materials.
Aluminum oxide is resistant and adapts well to roughing high strength materials such as carbon steel, alloy steel, bronze and hardwood.
Silicon carbide is the hardest and sharpest mineral. It is suitable for sanding non-ferrous metals: aluminum, brass, bronze, magnesium, titanium, … rubber, glass, plastics, fibrous wood, enamel… Silicon carbide outperforms any other abrasive in terms of its ability to penetrate and cut faster With little pressure.
Zirconium has the quality of self-sharpening that gives it a long service life in hard work of material removal. It is ideal for heavy metal roughing and wood calibration.
Ceramic aluminum oxide is a durable, resistant and dense abrasive. Its grain microstructure allows it to break during roughing, generating multiple new cutting edges. It is normally used in medium-high pressure jobs. It is recommended for carbon steels, forged steels and alloys containing nickel and cobalt.
2. Binder: According to the main use of different abrasive disc , there are porcelain, epoxy resin, plastic, metal, etc. Its key function is to bond the abrasive together to produce abrasive disc with a certain design.
3. Pore: Pore is also the main component of the abrasive disc . The purpose of the porosity is to reduce the fusion compressive strength of the binder and to store the abrasive disc materials. When the sharp part of the small abrasive is bald, the pores cause the fusion compressive strength to decrease and fall off, exposing new sharp abrasive particles, which is conducive to further processing.
There are many kinds of abrasive disc on the market now, and different types of abrasive disc have different use. Resin bond abrasive disc has irreplaceable grinding effect in industrial production. High-quality resin abrasive disc have better use effect, high strength, certain elasticity, better self-sharpening, and longer life. These significant advantages are determined by the raw materials for making resin bond abrasive disc.The following let me share with you the three important raw materials of resin abrasive disc that determine product quality!
1. Liquid phenolic resin. The fluctuation range of indicators such as solid content, viscosity, gel time and water solubility all have different degrees of influence.
2. The stability of mesh technical indicators. The glue content of the mesh has an impact on the strength, viscosity and cutting performance of the resin wheel. Therefore, we must continuously improve the performance, mainly in the fluctuation of the strength of the abrasive disc , the deformation of the slice, and the layering of the abrasive disc. Theoretically speaking, under the condition that the abrasive disc manufacturing process is stable and allowed, the higher the glue content of the mesh, the higher the strength of the abrasive disc, the better the bonding performance, and the more stable cutting and grinding.
3. Powder phenolic resin. The process of powder phenolic resin is an important performance index that affects the structure of the binder. The particle size affects the amount of wetting agent, and the content of volatile matter is also very important. In the actual abrasive disc production process, it is necessary to ensure the stability of the performance of each batch of powder resin, so as to ensure the quality of the abrasive disc.
In this operation the main factors to consider are: the thickness of the cutting disc, the thickness of the material to be cut, the substrate to be cut, the power of the machine, the pressure exerted and the heat provided.
According to the shape of the abrasive cutting disc we can classify them in:
Flat cutting disc: they are used for cutting. The diameters vary between 75 and 400 mm for portable machines and 300 to 400 mm for fixed machines.
Concave disc (with depressed center): its use is for cutting, with a diameter of between 75 and 230 mm, and for roughing, where the thicknesses range from 2.5 to 7 mm and the diameters from 100 to 230 mm for portable machines.
Pay attention to the quality of material during production, and only in this way can the overall quality of the product be guaranteed.Abrasive disc is the most important type of abrasive tool in cutting and grinding. Abrasive disc is a porous body made by adding binder to abrasive, compacting, drying and calcining. In the abrasive disc, the abrasive grains are bonded together by the binder, and the performance of the binder directly affects the performance and quality of the abrasive disc .
The quality of the resin is unstable, and the content of free phenol in the resin fluctuates. The so-called free phenol is the phenol remaining in the resin, and its molecular formula is C6H5OH. Long-term heating can crack the hardened resin and affect the strength of the abrasive disc;
2. The resin powder and urotropine are not mixed uniformly. As a hardener for resin, the amount of urotropine added is insufficient, and the resin hardening is not complete, which affects the strength and hardness of the abrasive disc; if the content is too high, excessive urotropine Not combined with resin, it decomposes and volatilizes during the hardening process, which increases the pores of the abrasive disc and reduces its strength and hardness.
3. The particle size of the binder is too coarse, and the particle size of the binder should be fine, which is conducive to the uniform distribution of the binder and the full contact of the hardener. If the particle size is too coarse, the molding material is not easy to mix evenly, which affects the hardness and strength of the abrasive disc.
In order to improve the strength and safety of abrasive products, various fibrous materials, such as glass fiber, asbestos fiber and carbon fiber, will be added as reinforcing materials in the manufacturing process of the abrasive tool. Among them, the most common and the most frequently used are glass fiber reinforced materials.
Fiberglass mesh is a standard reinforcement material in high-speed resin abrasive disc , and its functions can be summarized into four aspects.
First, the rotation speed of the grinding wheel can be increased to make cutting more efficient.
Second, it can reduce the fatigue of the abrasive disc and prolong the service life .
Third, once the abrasive disc is broken during cutting, the fragments of the broken abrasive disc can be retained, making the cutting operation safer.
Fourth, it can improve the lateral stiffness of the ultra-thin grinding wheel, making the cutting sharper and more wear-resistant.
The above four points are the main functions of the glass fiber mesh in the high-speed resin bond abrasive disc.
The cutting process is one of the most used in the metal sector. Abrasive disc cutting is the most common, versatile, comfortable and cheap.
The roughing process consists in removing the excess material from a piece to obtain the desired shape and dimensions. The main objective is to eliminate as much material as possible in the shortest possible time, regardless of the finish we are going to obtain.
We must take into account the factors that can affect the performance of the disk: the heat generated, the pressure exerted by the disk on the piece, the speed of work, and the projections of the rest of ore in blocks.
To know more: Abrasives and industrial machinery: products for a perfect finish
Inside the abrasive disc we find:
Flap discs, designed for roughing with great performance when the finish is important.
These sandpaper discs are made of sheets of abrasive cloth and fiber. They are available in many forms, abrasive minerals and special coatings to meet the needs of each application.
When the speed in the roughing is the determining factor we will make use of the fiber discs for the roughing of flat pieces.
They achieve a greater elimination of the material in the operations of roughing and deburring. There is a wide selection of diameters, minerals and grain on the market.
Finally, we must consider non-woven discs for the elimination of stainless steel welding. Their high cutting power allows them to eliminate weld seams while leaving a very fine finish that reduces the number of subsequent steps until the final finish of the piece.
They have an open three-dimensional fabric construction that allows a quick cut, keeping the surface cold and without embossment. They facilitate the removal of rust, weld spatter, scale and other surface contaminants.
The sanding process consists of those surface smoothing and refining operations performed with abrasives, both in wood, metal, plastics, glass, composites, varnishes, etc.
In several passes and using thinner grains every time, we can obtain uniform surfaces with different levels of finish. Normally this sanding is done with roto-orbital machines that have a suction system using discs with different amount of holes in their surface.
You may be interested. Basic recommendations for choosing the right abrasive products: rolls, discs and bands.
As we have said before, the abrasive materials used for the composition of the disc grains can be of natural or synthetic origin.
Natural abrasives, as the name implies, come from nature itself. The most common is emery composed of corundum and iron oxide. It is used for general polishing of metals in very fine grains.
On the other hand, there are synthetic abrasives. They are high quality materials, such as silicon carbide, aluminum oxide or synthetic diamond. Its manufacture is the result of the mixture of raw materials and chemical element. These types of abrasives are very modifiable, that is, their hardness can be adjusted according to what is needed.
