Abrasive discs are almost huge use in hardware tools . Normally we use the angle grinder with abrasive disc to cut metal / stainless steels or polish the surface of metal . The goal is to perform a good job .But , to achieve a good polished surface , it is necessary to know what the elements with which we can work and know how to do better for each occasion.
At CNDOME 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 the best for each of your projects. Therefore, this time we will explain everything about abrasive discs: what they are, the different types and their characteristics.
With this information, how to choose the right abrasive discs, you will know what exactly you need. So, come on, keep reading!
What is abrasive discs?
The abrasive discs are materials to be able to use a hardware tool that helps to cut, roughing metal materials . Its design, shape and composition will vary according to the use that will be given.
In general, its composition is based on crushed abrasive materials , combined together with resin bond , anchored and fixed to glass fiber mesh. These abrasive materials can be made of natural or synthetic aluminum oxide, silicon carbide, zirconium .
The use of abrasive discs in the steel industry is wide : 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.
The cutting process is one of the most useful in the metal sector. Abrasive disc cutting is the most common, versatile, comfortable and cheap way.
In this operation the main factors to consider are: the thickness of the cutting disc and materials to be cut, the power of the machine .
According to the materials of which the disc is made we can find two categories;
The common ones: that come from aluminum oxide, silicon carbide ,zirconium, or a mixture of these materials . They are ideal choice for working with soft, hard and semi-hard materials. They are used to cut, rough and polish steel, cast iron, ceramics, copper etc.
The super ones: 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 to very hard materials in a very precise way .
What is the Right Choice for Your Operation?
Abrasive products come in various levels of performance, which CNDOME conveniently labels “metal,” “inox” and “super.”
Which should you choose? Your choice involves balancing the results you want with the cost you’re willing or able to pay. If initial price is your primary consideration, choose good abrasives, but be aware that a lower purchase price up front may not end up being economical in the long run. When you’re running high-productivity applications and have to keep initial abrasive prices in mind, it’s time for better abrasives. Consider the best abrasive products when maximum productivity and lowest total cost are critical to your operation.
When testing abrasive products to determine the best solution for your operation, there are three objective measurements to consider; one of which must remain constant between products being tested. These measurements are time, material removed, and product wear. By holding one of these constant and measuring the other two, you can come up with an objective comparison between multiple products. For example, you could grind for 10 minutes with each product, and measure how much material was removed and how much of the abrasive products were lost; this is often measured by weight. Alternatively, you could run each product to the end of its life, while measuring how much material it removed, and how long it lasted. Finally, you could remove a set amount of material while measuring the time and abrasive wear. Each business has unique priorities; following these test methods will allow you to select the right choice to meet yours.
Forms of abrasive discs
According to the shape of the abrasive cutting discs we can depart them in:
Type 41(1) Flat cutting discs: they are used for cutting. The diameters vary between 75 and 400 mm for portable angle grinder and 300 to 400 mm for fixed angle grinder.Cutting discs are available in different thicknesses, and the type of wheel you select depends on the type, shape and thickness of the steel that needs to be cut. For standard everyday jobs on either stainless or mild steel using an angle grinder, choose a 1mm or 1.6mm thickness in your disc. For projects that involve thin metal such as sheet metal, choose a 1.0mm thinner cutting disc. These thinner discs will sheet metal faster and as such, minimise discoloration and leave less work in the clean-up of the surface of the metal once you’re done. For heavier steel cutting jobs where you need to cut through a significant thickness of metal, select a 1.6mm or 2.5mm thickness of cutting disc. However, it is important to note that thicker wheels cut slower and generate more friction and heat through the cut.This is a flat cutting wheel that allows for a maximum depth of cut. The main disadvantage of using a Type 1 wheel is that they mount closer to the guard making it more difficult for the user to see what they are cutting.
Typer 42(27) Grinding discs (with depressed center): its use is for roughing, where the thicknesses range from 3 to 6 mm and the diameters from 100 to 250 mm for portable angle grinder .Depressed center grinding wheels are the recommended grinder attachment for all weld grinding, pipe notching, general heavy stock removal – on mild steel. These discs with an aluminium oxide bond are most effective on mild steels, or softer metals and stainless steel.This design features more of a rigid feel while cutting, enhanced operator visibility of the cut, and the ability to flush cut as the raised hub allows for the locking nut to be recessed. These wheels are also available to quick change hub for ease of mounting.
Aluminium oxide is the most common abrasive used in grinding wheels. It is usually the abrasive chosen for grinding carbon steel, alloy steel, high speed steel, annealed malleable iron, wrought iron, and bronzes and similar metals.
Abrasive grinding discs
The roughing process consists in removing the excess material from a work 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 consideration the factors that can affect the performance of the disc: the heat generated, the pressure exerted by the disc on the work piece, the speed of work.
To know more:products for a perfect finish inside the abrasive discs we find:
Abrasives used in different abrasive discs
As we have said before, the abrasive materials used for the composition of the disc can be natural or synthetic origin.
Natural abrasives 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.
Aluminum oxide is resistant and adapts well to roughing high strength materials such as carbon steel, alloy steel, bronze and hardwood.
Selecting an Appropriate Abrasive: Abrasive materials do the cutting, and each type of abrasive offers a different balance of cost, durability, and performance. Let’s start by looking at the three most common abrasive materials:
Aluminum oxide is the most common abrasive grain and delivers very good cut rates and durability.It tends to have a lower initial cost for the user which lends to its popularity. 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 all the metals.Safety advice when using cutting discs.
Zirconium has the quality of self-sharpening that gives it a long service life in hard work of material removal.These wheels are used for high performance cutting with long life and feature a low cost-per-cut ratio. It is ideal choice for heavy metal roughing .
Silicon carbide is the hardest and sharpest mineral. It is suitable for sanding non-ferrous metals: aluminum, brass, bronze, magnesium, titanium , marble , stone etc. Silicon carbide outperforms any other abrasive in terms of its ability to penetrate and cut faster With little pressure.Widely used in stone cutting .
What grit size do I need?
When to select a suitable grit size: where the neatness of the surface finish is not essential to the project, a suitable grit can be used. Also, the suitable the grit, the more rapid the stock removal, which makes it more suitable for large areas of contact than fine gritted abrasives.
They are also the best option for soft, ductile and stringy materials such as soft steel and aluminium.
When to select a fine grit size: fine grits are used when the finish is integral to the success of the project.
Also, choose a finer grit when the project requires a closer, more precise operation over a smaller area of contact. Hard and potentially brittle materials such as glass, tool steel, and cemented carbide are most suited to the finer gritted abrasive.
What grinding wheel grade should I choose?
The grade indicates the relative holding power of the bond, which holds abrasive grains in a wheel.
- For hard materials such as hard tool steels & carbides
- For large areas of contact
- For rapid stock removal.
- For soft materials
- For small or narrow areas on contact
- For longer wheel life.
Just as work is carried out with precision, care and patience to achieve an impeccable result, it is necessary to remember that worker safety is essential. Next, we will give a series of basic tips when it comes to using abrasive discs.
Check the discs, tools which we are going to work with: before changing the abrasive disc that we are going to use in our tools, it is necessary to review, one by one, the discs that we are going to use. If one is damaged, broken or in poor condition, do not use it in any circumstances.
Place them correctly in the angle grinder: before starting working, make sure that the abrasive disc is perfectly positioned and that all the safety elements are correctly arranged. Never force the disc , or force the mounting or locking flanges, or use any machine that is in poor condition or malfunctions.
If any of the discs we are going to use are damaged, broken or in poor condition, we should not use it. Nor force the disc into the axis of the machine .
Ensure that the machine is turned off when not use : any manipulation of the machine, before or after use, should be done in the off position and, if possible, unplugged from the power outlet.
Follow the manufacturer’s instructions: it is essential to use the tools provided by the machine manufacturer to change the disc. You always have to go at the recommended speed under no circumstances .
Use proper protection: safety glasses and clothing is mandatory, not only recommended. In addition to gloves, safety shoes, dust masks, ear protection .
Maintain and handle the tools firmly: it is essential to hold the machine being used tightly. With both hands (in case of larger and heavier machinery) and trying to be as concentrated as possible to avoid unnecessary harm.
You may be interested: Why choose CNDOME Abrasives products for your company
Throughout the post we have explained everything related to abrasive discs to solve the doubts that normally arise.
At CNDOME we have the best quality in abrasive discs and other materials and solutions for professional cutting and surface polishing.