Keeping the rollers rolling in your roll grinding shop – partner with Grinding Techniques for perfect steel production

Steel manufacturing companies play a significant role within the South-African economy, not only by providing much needed jobs but also being responsible for the manufacturing of material to be used in various parts of the construction, mining and manufacturing industry.

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Grinding Techniques – a Tyrolit Swarovski Company, locally manufactures a variety of products under the brand name Andor for roll grinding used in the refurbishment of rolls in steel mills. From non-reinforced cut-off wheels used to cut steel samples prior to sanding with (NCH) No Centre Hole sanding discs, to cleaning of the surface in order for the metallurgy of the materials to be analyzed all the way to the roll grinding wheels in the grinding shops. Whether you need abrasives for laboratory work, or roll grinding shops, we offer a complete package to cater for all your abrasive requirements.

Due to the continuous use of rolls to their limit in the production line, an ever-high demand is placed in terms of wear resistance and surface structure of the rolls to promote increase in life and usability. Roll grinding shops within steel plants in particular require high quality grinding wheels to grind and prepare the rolls for use and re-use after refurbishment. Whether focusing on cold or hot mills, it is important to note that each mill presents their own challenge when it comes to machining rolls. Different rolls are used in the process from work rolls to back up rolls and these all have different profiles ranging from flat, CVC or Crown shaped. With new developments in the materials used for roll grinding such HSS, ICDP and forged steels various materials are now presented with a higher percentage chrome content for wear properties, and the advent of fully automated grinding machines, it is now of utmost importance to use reliable, consistent high-quality grinding wheels.

Hot mills require wheels offering fast stock removal rates and high performance, where surface finish tends to be less important. These rolls can range in diameters from 600mm to 800mm and with lengths ranging from 1600mm to 3400mm. In strip- and-plate mills, these diameters can go up to 915mm. Due to their extremely high stock removal rates, grit sizes ranging from 30 to 46 are normally preferred.

Cold mills on the other hand doesn’t have the same amount of material to be removed, but surface finish plays an important role. The work rolls in cold mills range in diameters from 300mm to 700mm and come with lengths up to 2500 mm. Grits sized between 46 and 150 will be preferred, as a finer grit is required to ensure a better surface finish.

Back up rolls in both hot and cold mills provide the necessary support and pressure to the work rolls and are larger in diameter going up to 1600mm. Usually made of cast and forged steels with a chromium composition of 2 to 5 percent, they are not ground as frequently as work rolls but have more material to be removed – in some cases material of up to 2 mm.

Common problems experienced in roll grinding shops such as grinding chatter, traverse marks and bruising can be eliminated when partnering with a manufacturer that understands the quality demands within the industry, and produce wheels of only the highest standards. Grinding Techniques’ research and development center regularly test and review products to ensure that grinding wheels produced conform and exceeds the required standards, and that optimum results, longevity and value are evident when using our products.

Since 1981, we have been a trusted precision wheel supplier to steel mills. Our years of expertise and the latest cutting-edge technology allow us to combine high quality grains and proven bonding systems to manufacture wheels with exceptional stock removal rates, cooler cuts and longevity.

Part of the Tyrolit group since 2014, we are also able to supply specialised Tyrolit grinding wheels specifically manufactured for wire rolling mills. As these mills make use of grooved tungsten carbide rolls, they have a diverse range of wheel designs with specific profiles. As these profiles get worn quite quickly, they need to be regularly ground. Metal bond is the wheel of choice due to its high-profile holding properties for this complex application. With the CSS Wire roll range of super abrasives made in either metal, resin bond or electroplated, you will get both longevity and high stock removal with quality that never disappoints.

Apart from manufacturing and supplying precision grinding wheels, we also carry a range of dressing wheels to dress the wheels back to its original profile, which can be tailor-made with regards to sizes used on different machines.

Grinding Techniques is able to offer a complete abrasive solution with products to suit various applications. With constant innovation, development and research, we have been the preferred precision partner for decades. Let us help you keep the rollers rolling. Contact our precision business development team for more information on customised specifications and sizes to suit your requirements.

For more information contact us: 011 271 6400 | info@grindtech.com | www.grindtech.com.

Getting the job done with Ceramic Abrasives

Ceramic abrasives are one of the newest innovations in grain technology. This high-performance grain has the ability to constantly re-sharpen as is wears, providing fast cutting action through its usable life. They provide the longest life and fastest cut rate of all coated abrasives. They represent the ultimate in performance, providing an aggressive, consistent cut under moderate to high pressure. Ceramic grains feature very small fracture planes which allow each grain to constantly re-sharpen and provide extremely consistent stock removal through its entire life cycle.

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Grinding Techniques proudly South African abrasive manufacturer and coated converter offers ceramic abrasive technology through our partnership with Starcke and Deerfos Abrasives. We offer a wide range of basic and finished products for almost every kind of application. At Grinding Techniques our aim is to provide you with the best coated or bonded abrasive product for your manufacturing process actively, objectively and reliably.

Typical applications where one would benefit from using Ceramic Abrasives includes but is not limited to:

    – Tough and hard to grind materials (Ceramic grains self-sharpening properties ensures a constant high material
    removal rate)
    – Heat and burn sensitive materials (The Top size cooling agent ensures a cooler cutting action eliminating heat
    buildup and premature dulling of the grains)
    – Applications where the output of parts in high volumes within the shortest time possible is a requirement. (Due
    to the fast cutting action of ceramic grains, the material removed is far superior to any other conventional
    abrasive grain in the same amount of time)

The quality of coated abrasives depends on numerous parameters such as the amount of grain and weight per unit area, the quantity of base, topcoat and curing temperatures. These parameters have been defined with a view to production and substantiated by quality assurance measures after every manufacturing step for each product. Not only do we manufacture abrasive products according to ISO standards, at Grinding Techniques we also strive to consistently meet and exceed maximum standards to ensure compliance with strict customer requirements.

Longevity and outstanding surface quality are the most important factors when it comes to supplying quality coated abrasive products. The world of “coated abrasives” presents itself with as much diversity as there are materials in order to achieve precise stock removal on metal, varnish, wood, natural stone, glass, plastics, ceramics and rubber. Our stock is easy to cut to all shapes, lengths and widths. Being a local converter of coated abrasive products, this is done according to customer requirements in order to facilitate and optimize delivery time, logistics and stock keeping for all parties concerned.

Coated abrasive products supplied by Grinding Techniques are designed to give the finishing touch to a wide variety of materials in the metal and wood industry and many more industrial sectors.

Contact us for the latest innovation in coated abrasives. Training and technical assistance is available from our product specialists who are ready to provide solutions to all your questions and processing issues.

Contact us on: 011 271 6400 | info@grindtech.com | www.grindtech.com.

Grinding Techniques remain the partner of choice for the Foundry Industry

Since the beginning of time, man found value in utilising various materials for the production of products related to self-sustainability. These materials evolved over time as technology and knowledge increased. From the humble beginnings of the copper age to the current highly sophisticated alloy age, casting of materials in usable forms and shapes remain a critical function.

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The oldest metal casting known to man is believed to be a frog casting in Mesopotamia around 3200 BCE. It was the first cast product to show the forming of a mould prior to casting the molten metal.

The bronze age was the era where tin and copper were mixed in the melting process, the new metal was developed in Turkey, Iran and Iraq. It was however the Egyptians that really perfected this process to a fine art and produced many a weapon and other industrial appliances, dominating the bronze age.

With the iron age that followed, the Chinese mastered the art of metal casting and the systematic production of metals around 1000 BC. They managed to mass produce cast tools and farming equipment and the world’s first cannons and gunpowder. Along with the change in metal production came the changes in the agricultural, religious and cultural spectrums. Europe was only able to produce its first iron products 1000 years later.

After the iron age, the industrial age followed. This era was known as the age of the technical revolution. The demand for cast products was on the rise, and soon new machines were developed to keep up with mass production and demand. Products now casted would include machine components, engine components, rail equipment, equipment for the airline industry, and a vast array of other consumer goods.

Through the evolution of castings, the basics still remained the same; make the mould, melt the metal, cast, cool and finish off.

As the science of metallurgy has grown in the past three hundred years, so too has the methods used to machine and shape the relevant products. In ancient times, sand stone was used to “file” the relevant pieces. Eventually bigger grinding stones were mounted on hand turned machines to grind and sharpen products. Today we have Ceramicists and Bio-chemical Engineers developing bonding systems for new artificial abrasive minerals being created. Machines that run at speeds exceeding 100m/s and achieving metal removal rated higher than ever before, whilst maintaining form accuracy to literally micron tolerances. Alloys are now being developed to be harder than glass, but still maintain the toughness synonymous with steel and metal related products.

As the science of metallurgy has grown in the past three hundred years, so too has the methods used to machine and shape the relevant products. In ancient times, sand stone was used to “file” the relevant pieces. Eventually bigger grinding stones were mounted on hand turned machines to grind and sharpen products. Today we have Ceramicists and Bio-chemical Engineers developing bonding systems for new artificial abrasive minerals being created. Machines that run at speeds exceeding 100m/s and achieving metal removal rated higher than ever before,
whilst maintaining form accuracy to literally micron tolerances. Alloys are now being developed to be harder than glass, but still maintain the toughness synonymous with steel and metal related products.

Grinding Techniques – a Tyrolit Swarovski company is uniquely positioned to offer application-based solutions. With more than 138 combined years of experience in manufacturing abrasive tools, both Tyrolit and Grinding Techniques are able to offer a comprehensive range of specialised products.

The product range for a typical foundry application includes, but is not limited to:

    – Hand Program (cutting and grinding discs)
    – Vitrified Grinding Wheels & Segments (precision grinding wheels, bench grinding wheels, laboratory surface grinding wheels, toolroom wheels)
    – Resin Bonded Wheels & Segments (swing-frame and pedestal grinding wheels)
    – Mounted Points, and Bullnose Cones
    – Tungsten Carbide Burrs
    – Water and Cabinet Paper Sheets
    – Flap Discs
    – Fibre Discs
    – No Centre Hole Discs
    – Bobbin Sleeves – Also known as even-run or spiral bands
    – Velcro Discs
    – Grinding Belts
    – Diamond & CBN Precision Grinding Wheels
    – Diamond Discs
    – Wire Wheels & Brushes

Our ability to manufacture custom made products to assist in optimising your fettling processes, is unrivalled in the industry today. Our understanding of metallurgy and equipment has propelled us to a become leading role player in the Foundry Industry. Our new innovative Premium Ceramic and Zirconia products are a prime example of market leading technology.

We offer an optimization service that allows for scientific comparison in all aspects of the grinding tool process from the material removal rate, to tool life comparisons and heat generation.

With one of the most comprehensive product ranges available in the Southern African market today, it is no wonder Grinding Techniques is the Industry partner of choice when it comes to the Foundry Industry.

For more information contact us: 011 271 6400 | info@grindtech.com | www.grindtech.com.

Must have abrasives for your toolbox

Any DIY enthusiast will inevitably need to cut, grind or sand something. A selection of abrasives is a must have in your toolbox for any DIY project. The market offers an extensive variety of abrasive products to suit various applications ranging from sanding to cutting and grinding at home.

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A broad range of cutting-and-grinding discs suited to many applications are available in different sizes and specifications. As discs are manufactured for both ferrous and non-ferrous materials, care should be taken when choosing the correct disc for an intended application and the information displayed on the disc label should be taken into account.
Apart from conventional cutting-and-grinding discs, some manufacturers carry a special purpose cutting-and-grinding disc range suited for specialised applications like radius cutting or cut-and-grind applications.

Most cutting-and-grinding discs are available in different sizes to fit both the 115-and-230mm standard diameter angle grinders. When choosing a quality disc, look out for a brand that offers fast and smooth cuts with high stock removal, durability and longevity.

Discs, rolls and paper all form part of coated abrasives and are used in numerous different applications. Whether you are sanding by hand to smooth down a surface or using a powerful belt sander or right-angle grinder to remove large amounts of material or shape a piece of wood within seconds, there are various products available to get the job done quick and effortlessly.
When choosing the correct sanding paper, you need to evaluate the intended application first. Cabinet paper more commonly known as “Wood Sanding or Garnet Sheets” is known as a cost-effective product that provides a fast cutting action and uniform quality finish on woodworking applications, and is ideal for sanding wood surfaces treated with primer, sealer, lacquer, paint and other liquid coatings and finishes. Waterproof paper sheets more commonly known as “Wet or Dry or Water Paper Sheets on the other hand, offer a bit more longevity, faster cut rate and a consistent finish with popular applications like light duty metal sanding, defect removal from paint surfaces, sanding of composites and fiberglass, as well as filler sanding, sanding between sealers and coats of paint or varnish.

Floor sanding rolls or 300mm X 1m rolls, is an economical product with great versatility for a variety of general-purpose applications and offer a heavy-duty backing that ensures fast cutting action – ideal for hand sanding, paint and rust removal. Handy rolls more commonly known as “Economy or Emery rolls” come with a flexible cloth backed material best suited for scouring, deburring, breaking edges and the removal of rust and scale from metals. All available in various grit sizes and 25, 40 and 50mm widths to make the choice for your application easier.
Abrasive discs are another product considered as an essential abrasive for your toolbox. Velcro backed sanding discs or sheets are used with power sanders and allow for a 40% to 50% faster cut rate with a more consistent and uniform scratch pattern than other conventional abrasives. Typical applications would include sanding wood and paint removal. Fiber discs, also used on power sanders are used for high stock removal and require a suitable back up pad.

Flap discs are bolted directly onto a right-angle grinder offering both high stock removal and sanding applications. With flap discs available in different grit sizes and specifications, they have become a popular alternative to conventional resin Fiber discs.

Whatever abrasive product you choose for your toolbox, you are sure to find a vast selection of options at your nearest retailer.

Article courtesy of Grinding Techniques: 011 271 6400 | info@grindtech.com | www.grindtech.com.

When tolerance is key it is vital to choose the correct partner for your precision grinding operations

The precision industry requires parts to have tighter tolerances and attain a specific surface finish whilst maintaining a low production input cost per unit, a challenging factor for many when wanting to maintain a competitive edge in the market.

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To achieve optimum performance, one needs to consider the complete grinding process. Correct coolant supply to the grinding wheel and workpiece is of utmost importance, machine spindle bearings must be in good condition to ensure vibration free grinding and sharp enough diamond dressers to open and not close the grinding wheel face are but a few factors that influence the overall process, vital to achieve optimal grinding results.

By choosing a partner that not only understands the importance of this but are in a position to provide technical know-how with the ability to locally produce products that meet these requirements, you can give your business the competitive edge with increased production output.

“We understand that using a grinding wheel is one of the most versatile and cost-effective methods to remove material from machined parts. A cutting action of hard and sharp abrasive grain particles from a rotating grinding wheel achieves this when the grinding wheel forces abrasive grains into the surface of the workpiece,” says a spokesperson for Grinding Techniques.

“An abrasive grinding wheel is a replaceable consumable that carries an abrasive compound on its periphery. They are manufactured of small, sharp and very hard natural or synthetic abrasive minerals, bonded together in a matrix to form the wheel. The grinding of precision components is only made possible by choosing the correct grinding wheel specification which is crucial for the achievement of high precision stock removal and or surface finish to very high tolerances. Due to the great number of variables involved, the grinding process is one of the most complex tooling processes.”

“With the advent of more exotic materials being ground, ranging from hard to grind metal sprays to tougher and harder tool steels, choosing the correct grinding wheel specification is becoming increasingly difficult.”

“Grinding Techniques make use of the latest technology in the ANDOR and TYROLIT range by using various high-quality minerals and proven bonding systems. This ensures a faster stock removal rate due to the self-sharpening effect of the grain and the properties of the bonding system that keep the grain in place for optimum performance. This combination is perfect to produce parts were tight tolerance and adequate surface finish is a prerequisite.”

“As a trusted precision partner, being the largest local manufacturer of precision grinding wheels in Sub-Saharan Africa, we at Grinding Techniques are able to engineer specific products for individual requirements with very competitive manufacturing lead times. Our comprehensive after sales service with technical expertise from our business development team and sales force ensure that we are with you every step of the way and ready to assist with any enquiries around the most optimum grinding process.”

For more information, please contact: 011 271 6400 | info@grindtech.com | www.grindtech.com.

Making the correct tool choice

In the modern age of industrial innovation, it has become more important than ever to analyse the performance of every tool at your disposal. The margin between success and failure, profit or loss may be determined by the small differences in production times and costs we often take for granted. More often than not we do things the same way we have always done them, even though the parameters and environment we operate in have changed.

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Why spend four hours battling to get a job ground and ready for shipping when one hour will do? Why employ three fettlers, occupy additional machines, PPE, electricity and other associated costs when the right tool could assist one fettler to be up to three or even four times more efficient? Why wait another day to invoice a job that could have been delivered today?

Today a wider range of alloys are being cast than ever before. Some alloys are lighter, and or harder, more abrasion-and-impact resistant, while others tend to react better to sub-zero temperatures or prove more heat sensitive than ever before. These alloys have been developed because the world we live in demands it. Seldom do we stop and put some thought into the machining, grinding and finishing of the said alloys until that moment of truth arrives. Panic stations! Luckily, our abrasive technology has developed at equally rapid rates. Manufacturing methods, bonding systems and mineral types have been evolving to keep up with the demands created by new modern innovative alloy introductions. At Grinding Techniques – a Tyrolit company, we are at the cutting edge of development and able to provide a solution for your abrasive requirements.

When one looks at the new range of ‘super alloys’ being developed, it has become increasingly evident that machining of these materials will be and is already a serious challenge. Grinding has proven to be one of, if not the preferred method, of shaping these alloys. Abrasive manufacturers all over the world are gearing towards the grinding, shaping and machining of these alloys with a far greater success rate over that of the machine tool bit manufacturers. New innovative products being developed have brought grinding and machining times of certain components down from 4 to 6 hours per part, to less than 24 minutes per part.

The Superflex Ceramic range of grinding tools are developed for rapid and accurate cool grinding on specialised alloy castings in excess of 700HBR. The results achieved when compared to conventional abrasive tools were almost incomparable. Grinding times on these hard materials were reduced by more than 66%, and as a result of the shortened grinding times we were able to lessen the heat being generated through friction by significant proportions with a noticeable cost saving as a result. Scrap rates as a direct result of heat cracks are now something of the past.

The ceramic range as good as it is for chrome and abrasion resistant materials does not provide the same performance level on cast iron, SG iron, manganese and steel foundries. Due to the fact that the grinding mineral offers a sharper, more aggressive grind on contact, but the bonding system employed breaks down in a different manner to that of conventional grinding wheels developed for softer materials. Selecting the incorrect tool – reduces the efficiency of the grinding tool on application and increases the cost to a point where it is just not viable to use.

So where does one begin when choosing the most appropriate tool for the job at hand? It starts by challenging yourself to achieve a more desirable result and produce a better end product, at a satisfactory cost level for the specific application.

You need to ask yourself what would you like to achieve? Faster grinding times with less of a bottleneck in your fettling bay? Lower grinding cost per component? Reduction in machine cost, or replacement cost? Better aesthetic finishing? All of them or at least a combination of the above are possible by selecting the correct abrasive type.

Grinding Techniques, a Tyrolit company, offers a comprehensive range of abrasives geared towards achieving your required optimum result. With more than 100 years of manufacturing experience behind us, we more than willing to conduct trials, assist with application optimisation, and work along-side you to tailor make a solution that attains your required results. Our comprehensive product offering uniquely qualifies us to assist in optimising your foundry requirements and making the correct tool choice.