Grinding Techniques – The Preferred Precision Grinding Partner since 1981

The precision grinding industry is a vast and complex environment, that demands premium grinding media to deliver optimum performance and results.

gt_blog_image

With a range of different applications that require unique and specific results, several wheel shape derivatives are available.

Apart from the shape 1 straight wheel, used for conventional grinding applications, grinding wheels come in a range of other shapes and sizes including the well-known cup wheels.
Cup wheels can range from either a shape 6, which refers to a straight cup, shape 11, commonly known as a “flared” cup wheel, or type 2, which resembles a cup wheel with a ring shape – all very popular for grinding applications in industries, like toolroom, automotive, aircraft, engine components and wood working manufacturing.

Used for either producing new components, or regrinding and/ or resharpening of the different components after becoming blunt due to use, typical tools ground with shape 6, 11 and 12 cup wheels, include broaches, cutters, millers, reamers, drills, taps, and dies.

Most cup wheels are used for applications on fixed mechanical tool and cutter grinding machines, ranging in diameter size from 50mm up to 150mm, with a thickness starting from 10mm going up to 80mm.

Shape 6 and 11 cup wheels are usually manufactured with rim widths ranging from 4mm up to 13mm and are mainly manufactured with a vitrified bond, containing either Aluminum Oxide or Ceramic grains.

Choosing the appropriate grain when cup wheels are manufactured requires careful consideration of the material being ground, desired results as well as the amount of stock removal required.
During precision grinding applications, burning of the workpiece, is often a common challenge, which can be overcome by either using coolant during the application, or making use of a dressing application which can reduce, or eliminate this problem.

By creating chamfer on the rim with a handheld dressing stick, the cup wheel’s width will be thinned out, which will effectively decrease the contact surface area of the cup wheel to the workpiece, eliminating burn during application.

For grinding applications where a workpiece contains some heat sensitive materials, the use of a coolant during application should be considered as to minimise burning of the workpiece. In cases where workpieces consist only of heat sensitive metals, cup wheels manufactured from Ceramic grains should be considered due to its cool grinding properties.
Apart from delivering reduced heat during grinding applications, Ceramic grains are the most technologically advanced, offering self-sharpening properties with excellent stock removal in the shortest possible time. Effectively, this reduces overall downtime, as more components can be ground in between dressing applications, which, in the long run, not only reduces overall labor costs, but electricity, machine wear and tear, as well as consumable costs.

Also used in the manufacturing of cup grinding wheels, known as the purest grain, is White Aluminum Oxide, which with its high friability, is suitable for grinding heat sensitive steels, delivering optimum stock removal during application, without causing burn to the workpiece.

When it comes to applications on cemented carbide parts, Green Silicon Carbide grain will be the prerequisite, as it possesses both the extremely sharp grain characteristics, as well as the sought-after friable properties. Grinding wheels manufactured from Green Silicon Carbide usually range in grit sizes of 46 to 220, with a hardness grade ranging from H to N.
When manufacturing these wheels, the combination of grain and hardness are determined by the hardness of the workpiece to be ground, as well as the type of grinding application and required finish.

Grinding Techniques have been manufacturing ANDOR precision grinding abrasives locally since 1981 and specialise in custom grinding application solutions.

Whatever your abrasive requirement, our application specialists are ready and available to analyse your requirement and propose a cost-effective solution.

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

Grinding Techniques – Your partner in abrasive solutions for the Construction Industry

The South African construction industry is multi-faceted and complex. With projects ranging from large scale green energy installations, to smaller at home DIY and general maintenance projects, it can be further classified into buildings, infrastructure and industrial construction. With the advancement of science and technology, we are seeing improved materials being utilised, as well as new composite and hybrid materials. According to various sources, the construction industry is projected to grow by 4% to 6% in the short term and by only 1% to 2% over the next 3 to 5 years.

construction-industry

The construction industry has come a long way from the Stone Age, where buildings were first built from wood, mud or rocks that were simply packed on top of each other. While these materials are still very popular in a much-updated guise (granted, that they have improved significantly in quality and usage), newer, more advanced techniques and materials are becoming much more prevalent. Hybrid materials are now being used in electronics, mechanics, energy conversion and storage as well as self-healing coatings for corrosion control paints. Hybrid construction methods also involve utilising multiple material types (such as wood, steel, glass) in new and unique ways. Composite materials provide several benefits (depending on the project requirement), such as a higher strength to weight ratio. Ceramic, carbon, and polymer composites are becoming very popular in the green energy generation, aircraft and aerospace, civil and general construction, as well as automotive industries.

Considering that the construction industry employs in the region of 8% of the South African workforce, the need for products offering “Value for Money” has become more important than ever before. The focus on occupational health and safety is now more than ever in the spotlight, which highlights the need for correct product selection to ensure a safe working environment.
The general lack of infrastructure projects, long process of contracts being approved and awarded, and pandemic induced factors means that more value is now required out of previously over-looked costs – consumables such as abrasives being an example. It is easy to find an abrasive product, but the question to ask is what kind of result is required.

Grinding Techniques, as a local manufacturer and supplier of premium abrasive solutions, is at the forefront of product development suited to these changing conditions. Constant testing and development are required to ensure that these new age materials are processed within the required tolerances and at an economical rate. Ceramic grains and super abrasives (diamond and CBN) are becoming the popular choice, but proper training and education is required to ensure that operators understand the differences, and correct, safe usages of these products. The loss of skilled workers over the years has seen a higher percentage of unskilled workers operating on construction projects. Grinding Techniques attempts to mitigate some of this risk by also offering training programs at retail and informal market levels.

Grinding Techniques manufactures true “Value for Money” abrasives that are tailored to optimise any construction project. The Superflex Professional range of cutting and grinding discs will help to reduce material wastage, reduce overall working time, and provide a better finished product. Superflex and Andor diamond saw blades are optimised for construction material applications. Ceramic coated abrasive products (such as sanding discs and belts) for Stainless Steels and other difficult to work materials, provide superior results.
The introduction of cordless Power tools on construction sites have brought about new dynamic in cutting and grinding, in that we now see a much higher percentage of cordless tools being used on construction sites, abrasive products also need to be optimised to retain the best possible balance of performance for these machines and this is where Grinding Techniques can assist you in selecting the correct abrasive product for your application.

We have, of late, seen a big shift towards renewable energy and energy saving projects in South Africa and across the world. Using abrasive products that reduce operating time, speed up processes and reduce waste will go a long way to assistin the greening process of the construction industry. It may only be a small part to play, but the sum of all small changes can and will add up to a major shift in the right direction.

Grinding Techniques is equipped to assist in every phase of a construction project to ensure that product selection is optimised to meet these goals.

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

Flap Discs versus Grinding Discs – when to use what?

With so many grinding products available on the market, how does one know what the best choice will be – should I opt for a right-angle grinding disc, or will a flap disc suffice and what exactly is the difference between them and is it enough of a difference to make a difference?

A smooth, well finished metallic surface may be required for either aesthetic or functional reasons. Without a good start, one cannot expect to achieve a good finish and selecting the appropriate product will require some insight into the required end result, be it painted, polished or raw material look.

Considering that the go-to disc for stock removal has always been the rigid abrasive grinding disc, with the use of flap discs becoming more and more popular, one needs to first understand what an abrasive flap disc is. Unlike a traditional resin fiber disc, the abrasive flap disc is a single unit that contains its own backer. Abrasive flaps are arranged radially and in an overlapping format on the face of the backer and glued into place. Flap discs come in various shapes, sizes, and formats with distinctly different shapes.

Shape or Type 27, also known as flat, is best used for blending, smoothing, or finishing applications and suited more to flat surfaces being ideal for deburring and edge grinding applications. Shape or Type 29, commonly referred to as conical, works best for aggressive stock removal, where speed and cutting ability is required. The Type 29 provides a greater contact area with the angle of the disc for improved stock removal on flat surfaces.

Flap discs are manufactured from a range of different grains, each with its own properties suited to specific applications.

Alumina Oxide, red brown in colour, is the most cost-effective grain and usually reserved for light industrial or general-purpose jobs on soft metals and woods.

A more premium, high-tech grain, Zirconia, is blue green in colour and this grain self-sharpens as it wears away during application. Designed to provide high stock removal with fast cutting, this grain offers reduced heat generation with a cooler grind in the material.

Ceramic grains, offering the highest level of stock removal, and mostly red in colour have precision shaped grains that self-sharpen with a unique crystalline structure, which remains sharper and more effective over a longer time period, giving the product extensive longevity. Heat generation is further reduced due to the way that the grain breaks down during usage.

Grinding Techniques manufactures the Superflex flap discs using both Zirconia, and Ceramic grains, with the Premium range featuring a flap disc containing special anti-clogging properties within the ceramic grains specifically manufactured for non-ferrous metals.

Superflex Abrasive flap discs come in 40, 60, 80 and 120 grit sizes and different diameters to fit standard right-angle grinders. Coarser or finer grits are available on request. A coarser grit disc is used when a quicker removal rate is essential and surface finish is less important, whereas finer grits are usually reserved for blending, smoothing, and finishing operations, where surface finish is more important. They are typically used in the latter stages of the process.

Using flap discs carry a few benefits in comparison to conventional grinding discs.

As a flap disc provides a more controlled stock removal application with cooler cutting, less re-working of the piece is needed as discoloration is limited, even on heat sensitive materials where conventional grinding discs could potentially form fine hairline cracks resulting in damage on the piece, a cooler grind from the flap discs can avoid this to a great extent.

Two applications are possible with one product. An angle grinding disc has the tendency to create deep gouges due to the extremely aggressive design. A piece ground with an angle grinding disc will need to be retouched with a secondary product to improve the finish. With an abrasive flap disc, both stock removal and finishing can be done with the same product, at the same time. This reduces down time for disc changes, resulting in a reduction in overall contact time.

Operator fatigue is significantly reduced. Not only are abrasive flap discs substantially quieter than angle grinding discs, but they also create less vibration due to the lower pressure being used during application. Flap discs are lighter, which added to the lowered vibration, puts less strain on both operator and machine.

On the other hand, if you are only looking for fast stock removal and are not concerned by or requiring a smooth finish, then the traditional right-angle grinding disc may well be your best answer. Grinding discs are suitable for metal, non-ferrous and stone applications across a range of machine sizes. The main function of a grinding disc is fast material removal. Various industries utilize grinding discs successfully in their operations such as foundries and engineering shops. Depending on the application a range of grinding discs are available, from the standard Industrial range suitable for mild steels right to the Premium range suitable for high alloy and heat sensitive materials. As with flap discs, grinding discs are available in two shapes; a Shape or Type 27 for general grinding applications and a Shape or Type 28 which is a dome-shaped disc suitable for more aggressive stock removal at an angle which facilitates reduced operator fatigue as the disc design automatically provides the right approach or grinding angle without the need to manipulate the grinding machine.

To decide between a flap disc and a grinding disc one now needs to answer the following question – what does my end product need to look like? If your product needs to be painted, coated, polished and/or be provided raw with a good finish, then the abrasive flap disc is your best option, if you need fast material removal without the need for a smooth surface finish you may want to consider the grinding disc as an option.

In conclusion, the Superflex abrasive flap discs will provide fast, cool grinding regardless of the material. Coupled with the improvement in operator fatigue, the versatile flap disc does look to be the future product of choice.

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

ANDOR – Premium partner for all your Internal Precision Grinding

When bores and holes – straight or tapered need to be ground to specific tolerances and finishes, internal cylindrical grinding is the application of choice. One of the major challenges faced with this grinding application, is the restriction of coolant, as the grinding wheel is encapsulated by the workpiece.

gt_blog_image

This encapsulation effect increases the area where the grinding wheel is in contact with the workpiece to be significantly bigger compared to that of external cylindrical grinding. The specification of these wheels is usually a coarser grain size, softer hardness and a more open structure compared to wheels used for external cylindrical grinding.

Dependent on your application, there are different machines available for this specialised grinding application. With Universal Cylindrical, or Plain Internal grinders, the grinding wheel spindle rotates in a fixed position and the workpiece rotates and reciprocates along the grinding wheel.

When parts that are too large to rotate, need to be ground, the Internal Planetary grinder is the grinding machine of choice. During this process the grinding wheel spindle rotates and moves in a circular / planetary movement, with the workpiece not rotating, but reciprocating to attain traverse.

For internal centerless grinding, a Chuck-type Internal grinder is used which allows for the workpiece to rotate in a fixed position and the grinding wheel to rotate and reciprocate through the length of the hole or bore being ground.

Apart from the grinding wheel setup, selection, and, workpiece characteristics, other key points to consider include, the amount of stock to be removed, condition of the grinding machine, speed of both the grinding wheel, and workpiece as well as the use of coolant during the grinding application.

When selecting a suitable grinding wheel, one should be careful not to select a wheel too large in diameter for the workpiece to be ground. As this could not only result in the wheel blocking the bore, but also prohibit the grinding swarf from escaping, causing the grinding wheel to rub against the workpiece with no actual grinding application, ending in the workpiece heating and distorting. To counter this problem the general rule of thumb is to select a grinding wheel 66% to 75% of the size in ratio to the internal diameter being ground. This will allow free flow of coolant between the grinding wheel and workpiece.

During the grinding application, it is critical to ensure that there is sufficient volume of coolant with the correct direction and pressure into the contact zone, to prevent the workpiece from heating up, causing it to crack and warp, or clog as grinding swarf cannot be washed away.

Considering the type of material to be ground, and its hardness is equally important. With hardened materials, a grinding wheel with a finer grit size is more suitable, as it is easier for a finer grit to cut through the material than a coarser grain. Our Andor grinding wheels have a superior bonding system that l keeps the grain in place long enough to facilitate the grinding application and release the dull grain at the optimum point to expose new sharper grains. Due to this, we are able to manufacture wheels with specialty grains such as Sintered Aluminium Oxide which is known for having a higher stock removal rate and cooler grinding characteristics compared to other Aluminium Oxide grains. Using this type of grain significantly decreases the amount of time it takes to grind difficult materials, saving on both labor and electricity costs.

Further to this, the amount of stock removal, and the required finish should also be taken into account. A coarser grain wheel will remove material quicker, but not necessarily produce a very good finish, whereas a finer grain wheel will take longer to remove stock but will render a much finer finish.

With Grinding Techniques, it is easy to find the correct solution to your precision grinding application. Our Business Development team is able to assist with a premium basket offering of specialised abrasive solution to the precision grinding needs of your business.

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

Your Premium Surface Grinding Partner

When precision in your surface grinding application is a non-negotiable, turn to Grinding Techniques for all your premium abrasive requirements. Surface grinding is an abrasive grinding process that makes use of various grinding media to grind either metallic or non-metallic workpieces to achieve a perfectly flat, or parallel surface with a specific surface finish. Types of grinding media used for this application, include grinding wheels, cup stones, and segments.

blog_image

With different types of surface grinders available in the market, ranging from horizontal-spindle to vertical-spindle with reciprocating and or rotary table machines, to face grinding machines, it is essential to note that the type of grinding media should carefully be considered in order to provide the best result for each application.

Straight grinding wheels are typically used with horizontal-spindle reciprocating and or rotary table grinding machines where cup or cylinder grinding wheels and segments are more suited to vertical-spindle reciprocating and or rotary table grinding machines. When it comes to using Face grinding machines, cylinder grinding wheels and segments are the grinding media of choice.

Some of the machines are specifically designed for grinding intricate small workpieces, and others are for heavy machining of large workpieces such as forgings, castings, or long flat parts such as guillotine blades.

Most surface grinding machines make use of magnetic chucks to ensure that the workpiece is kept in place while the surface is ground to high precision. Every time a workpiece is ground and removed from the magnetic chuck or table it needs to be cleaned properly to ensure that no debris is left behind to obscure the new workpiece lying flat on the surface grinder’s table. Our Andor combination oil stone is the perfect tool for this application to ensure a perfectly smooth surface without any burrs.

When choosing your grinding media, certain factors need to be considered. Apart from the type of surface grinder, its power, speed, and condition, the workpiece’s properties also contribute to making the right choice e.g.  the material and hardness of the workpiece, the overall dimensions, the amount of stock removal required, and the desired finish are all important elements that play a fundamental role.

Another crucial factor, frequently overlooked, is the grinding fluid and its concentration as it is required to cool the workpiece during the grinding application, making sure the debris is washed away and the wheel is kept clean and open whilst in operation. Coolant that is not used with the correct percentage mixture or pH level can have severe consequences on the performance of the grinding wheel, either causing the wheel to clog up or not rendering the desired surface finish.

Once all the above factors have been considered, a grinding media can be specified.

Grain types are specifically designed for applications on various substrates ranging from mild steel, to abrasive resistant and extremely hard to ground materials. The correct combination of grain type, grain size, hardness, structure, and bond type will ensure that the workpiece is ground to the desired tolerance and finished in the shortest amount of time, saving on operational costs. Grinding media is manufactured from various abrasive grains, including white Aluminum oxide, which is the most pure and friable grain perfectly suited to hard metals where a cool grind is required with minimal burn. Ceramic grain is known for high stock removal rates on hardened materials and will produce an even cooler grind than Aluminum oxide. Producing class leading Andor surface grinding media, needs class leading bonding systems. These bonding systems, whether vitrified or resin, are extremely important as it is the glue that keeps everything in place. Even the best grinding wheel with the best possible grain on the market, needs a high-quality bonding system. Our proven Andor bonding systems coupled with ceramic grain works optimally to ensure the grain is kept in place long enough and is released by the bonding system just in time before it becomes too blunt, thereby producing the next sharp grain to continue with the grinding application. Not only does this ensure high stock removal rates, but it also ensures increased longevity throughout our Andor range. 

Our Andor premium surface grinding range is suited to all these applications and more. We are able to produce surface grinding wheels in sizes ranging from 150mm up to 750mm in outside diameter. All our grinding wheels are manufactured to OSA, ISO 9001, and EN quality standards, which ensure both safe and quality products.

Our Andor grinding media is finished with the latest finishing methods,  specifically designed to machine grinding wheels to the desired dimensions and international tolerances.

As a specialised abrasive manufacturer, we are able to assist with a custom precision grinding solution to any application. For more information, or assistance, contact our Business Development Team.

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

Your partner in abrasive solutions for the Construction Industry

The South African construction industry is multi-faceted and complex. With projects ranging from large scale green energy installations, to smaller at home DIY and general maintenance projects, it can be further classified into buildings, infrastructure and industrial construction. With the advancement of science and technology, we are seeing improved materials being utilised, as well as new composite and hybrid materials. According to various sources, the construction industry is projected to grow by 4% to 6% in the short term and by only 1% to 2% over the next 3 to 5 years.

gt_blog_image

The construction industry has come a long way from the Stone Age, where buildings were first built from wood, mud or rocks that were simply packed on top of each other. While these materials are still very popular in a much-updated guise (granted, that they have improved significantly in quality and usage), newer, more advanced techniques and materials are becoming much more prevalent. Hybrid materials are now being used in electronics, mechanics, energy conversion and storage as well as self-healing coatings for corrosion control paints. Hybrid construction methods also involve utilising multiple material types (such as wood, steel, glass) in new and unique ways. Composite materials provide several benefits (depending on the project requirement), such as a higher strength to weight ratio. Ceramic, carbon, and polymer composites are becoming very popular in the green energy generation, aircraft and aerospace, civil and general construction, as well as automotive industries.

Considering that the construction industry employs in the region of 8% of the South African workforce, the need for products offering “Value for Money” has become more important than ever before. The focus on occupational health and safety is now more than ever in the spotlight, which highlights the need for correct product selection to ensure a safe working environment.
The general lack of infrastructure projects, long process of contracts being approved and awarded, and pandemic induced factors means that more value is now required out of previously over-looked costs – consumables such as abrasives being an example. It is easy to find an abrasive product, but the question to ask is what kind of result is required.

Grinding Techniques, as a local manufacturer and supplier of premium abrasive solutions, is at the forefront of product development suited to these changing conditions. Constant testing and development are required to ensure that these new age materials are processed within the required tolerances and at an economical rate. Ceramic grains and super abrasives (diamond and CBN) are becoming the popular choice, but proper training and education is required to ensure that operators understand the differences, and correct, safe usages of these products. The loss of skilled workers over the years has seen a higher percentage of unskilled workers operating on construction projects. Grinding Techniques attempts to mitigate some of this risk by also offering training programs at retail and informal market levels.

Grinding Techniques manufactures true “Value for Money” abrasives that are tailored to optimise any construction project. The Superflex Professional range of cutting and grinding discs will help to reduce material wastage, reduce overall working time, and provide a better finished product. Superflex and Andor diamond saw blades are optimised for construction material applications. Ceramic coated abrasive products (such as sanding discs and belts) for Stainless Steels and other difficult to work materials, provide superior results.

The introduction of cordless Power tools on construction sites have brought about new dynamic in cutting and grinding, in that we now see a much higher percentage of cordless tools being used on construction sites, abrasive products also need to be optimised to retain the best possible balance of performance for these machines and this is where Grinding Techniques can assist you in selecting the correct abrasive product for your application.

We have, of late, seen a big shift towards renewable energy and energy saving projects in South Africa and across the world. Using abrasive products that reduce operating time, speed up processes and reduce waste will go a long way to assistin the greening process of the construction industry. It may only be a small part to play, but the sum of all small changes can and will add up to a major shift in the right direction.

Grinding Techniques is equipped to assist in every phase of a construction project to ensure that product selection is optimised to meet these goals.

Contact our Business Development team today for a premium solution to your construction application.

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

Precision to the point with Tungsten Carbide Burrs

When your application requires a precision cutting and or milling process, turn to Grinding Techniques for high quality Tungsten Carbide Burrs that will effortlessly shape, cut, grind, or remove burrs, sharp edges and excess material from your workpiece, castings, and forgings.

Website-Article-Burrs

Tungsten Carbide Burrs also known in the industry as either rotary files or die grinder bits, are considered precision tools commonly used in industries like Foundries, Shipbuilding, Aviation, Automotive and Metal fabrication shops. Due to their versatility, they are suitable for a variety of materials ranging from Steel, Stainless Steels, Aluminium, Cast Iron, Plastics and Wood.
With so many cut styles available in the market, it is important to choose the correct configuration for your specific application. Some of the configurations available includes Single cut, Chip-Breaker and the premium Double cut burr.

A single cut burr typically has a single flute which causes the chip removed from the material to be sharp and long, this burr is known as a general-purpose design suited to Cast Iron, Steel, and other Ferrous metals.

The Chip-Breaker cut makes use of the same single flute design, but with the inclusion of a spiral cut in the opposite direction to break the single flute and produce smaller swarf pieces and improve operator control during application.

Double cut burrs on the other hand have flutes cut in a cross-cut direction which enables a double cut during every rotation of the burr, which not only minimizes the time it takes to remove the excess material, but also ensures that the swarf removed, is being cut into very small pieces. The Andor Speedline range of Double Cut burrs also has the added advantageous of ensuring the swarf removed is blunt and won’t penetrate the skin to further support operator safety. The Double cut is known as the most versatile of the range.

Due to the smaller swarf being produced, the Double cut burrs also produce a smoother finish compared to that of a Single cut or Chip-Breaker cut burr.

Along with the different configurations one also need to choose the correct shape for your application.

The shape will depend on the profile or cut that will be required on the workpiece. Ball shaped burrs are perfect to create concave cuts or to hollow out an area. When you need to round off edges, a tree-shaped burr will be best suited. Parts where a V-cut is required or where the rear side needs to be chamfered will need a burr with an inverted cone.

When using a tungsten carbide burr, it is important to remember due to the flute design, they are manufactured to be used with die grinders or pneumatic rotary tools and not with normal drills. Their optimal performance speed rating is ranging from 17,898 rpm to 39,773 rpm, (dependent on the size of the head of the burr), if used in a drilling machine running at around 2,000 to 3,000rpm, which is significantly less than a die grinder or pneumatic rotary tool, cutting effectiveness will be hindered, the burr could chip and clog up, and excess heat will be generated that could lead to the premature failing of the shank of the burr potentially causing detachment from the shank.

Always ensure your burr runs at optimal speed, a general guideline to remember, is, the smaller the dimension of the burr the faster the optimal speed of the burr, and the bigger the dimension of the burr, the slower the burr needs to run at.

When using a tungsten carbide burr it is important to allow the tool to do the cutting work and not to apply too much pressure, as excessive force will cause the burr’s cutting edge of the flutes to chip away or turn blunt too quickly which will instantly reduce the longevity of the burr.

To avoid the burr to dig and grab into material, it is important to move it around during application and not hold it in one section for too long.

Due to the extreme hardness of Tungsten Carbide Burrs, they can be used on more demanding jobs tolerating higher temperatures than that of HSS burrs, which are prone to soften under higher working temperatures.

Whatever your requirement when it comes to Precision tools, we have a customised solution to your application.

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

Choose your finish with the Superflex Non-woven Abrasive Range

Non-woven abrasives are a three-dimensional web of fibers with globules of resin and abrasives embedded into the network of fibers. Typically, the fibers are nylon or another synthetic material. The abrasive types can range from silicon carbide to aluminum oxide or ceramic alumina.

Some of the main benefits and advantages of non-woven abrasives is that they are waterproof, rinsible and resilient due to their open-mesh construction. Used wet or dry, non-woven abrasive products enable the user to achieve a consistent, uniform finish, and conformability to irregular surfaces, with minimal material removal, smearing and discoloration of the workpiece.
Grinding Techniques – a Tyrolit company, is proud to have launched the Superflex range of non- woven products, available in many different shapes, sizes, and materials dependent on application and whether used by hand or machine.

The non-woven hand pads and rolls are mainly used for cleaning and processing surfaces using orbital sanders or hand-guided grinding. A wide range of specifications offer the user a variety of surface finishing options. The range extends from coarse specifications for cleaning weld seams through to very-fine polishing applications. A consistent finish with proven longevity is guaranteed thanks to the abrasive grain that is impregnated into the entire fleece of the product and not only located on the surface. Flexibility is also ensured by the abrasive fabric that adapts perfectly to the geometry of the workpiece surface.

Should your application require a portable power tool to achieve your desirable finish more timeously, Grinding Techniques offers numerous non-woven products suitable for a 115mm right angle grinder. This product offering includes but is not limited to Superflex Non-Woven Flap discs, Premium Pre-Polish, Polishing discs, and Rough Cleaning discs.
One of the most common challenges when it comes to surface preparation or polishing is getting all the components matched to one another. With Superflex everything you need is available from one source of supply and perfectly matched. With our range of products, you can achieve a mirror finish in only three steps without unwanted burning or discoloration normally caused by overheating.

Superflex Non-Woven Flap discs can be used for various applications on different materials. It removes and blends all rough scratch marks on surfaces. The multi-dimensional flap design reduces clogging and prevents unwanted material discoloration.

To prepare surfaces for polishing, you require a sturdy, high quality product. The Superflex Premium Pre-Polish disc consists of several layers of abrasive fabric ensuring longevity and sturdiness. This allows the disc also to be used for smaller deburring jobs. The ideal operating speed for non-woven abrasive products are typically 60% of the total speed of a 115mm angle grinder but the product has been developed to achieve good results even on non-adjustable speed angle grinders.

Compared to conventional felt discs the Superflex Premium Polish disc is constructed from highly flexible flaps for optimal heat distribution and cool grinding. In doing that the Premium Polish disc avoids undesired discoloration, when used in conjunction with a polishing paste, a perfect mirror finish is achieved on your workpiece. This disc has also specifically been developed to achieve exceptional results even on non-adjustable angle grinders.

When it comes to removing rust, paint, and varnish with the least possible effort or preparing surfaces for welding, soldering, or anodizing, the Superflex Rough Cleaning disc constructed from highly porous nylon fibers, and evenly treated with aggressive abrasives, is able to stand up to any challenge. This disc resists loading or smearing and offers guaranteed longevity with an even scratch pattern, and low heat generation with quiet, stress-free working.

Apart from this, Grinding Techniques also offers an extensive range of Convolute and Unitized Wheels manufactured with the latest technology to provide the desired finish combined with a high tear resistance and exceptional longevity. The main applications for these products are deburring, blending, and finishing of a variety of materials like metals, plastic, and composite materials. Some applications include design objects, surgical instruments, aircraft engines, components of turbines, marine vessel stainless steel and metal parts, chemical and food processing tools and tanks, cutlery and jewelry, hand tools, threaded parts, jet blades and vanes.

Although Unitized and Convolute wheels are similar types of products, they each have important differences, Unitized being smaller in diameter, usually 150mm or less, making them ideal for use on portable power tools, where Convolute wheels, usually 150mm in diameter, or larger, are ideal for stationary or robotic machines. All products are available in several different densities, grit types and grades.

Should you require custom solutions or specifications for certain applications, contact our business development team for more information to suit your requirements.

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

Stainless Steel Metal Fabrication – Get the RIGHT tool for the job

When it comes to fabrication with stainless steel, using the right tool is essential for achieving optimum results. Grinding Techniques has a complete range of products specifically manufactured for all stainless-steel cutting, grinding and finishing applications.

blog_image

One of the most important factors to consider is the non-contamination of the material during application. Our Superflex “Inox” range, is specifically manufactured for stainless steel. Free from iron, sulphur, and chlorine, it will not burn or discolour the material. Available in various diameters and thicknesses, discs may be selected dependent on the intended application.
A popular product is our Superflex Professional Slimline range. These discs come in a thickness of 1.0mm up to 2.5mm and will provide a clean, fast cut with less to no burrs to be reworked after cutting. Particularly suited to thin stainless steel sheet metal, this product delivers effortless cuts with great results.

Another versatile product that can be used for both grinding or stock removal, and finishing, is our Superflex Flap Discs – particularly useful when it comes to welding applications where a smooth and seamless finish is required after the welding operation. Available in 4 tiers ranging from Evolution suited for general purpose applications, to Premium Inox specifically manufactured for stainless steel to ensure the ultimate surface finish. Manufactured from high-tech Ceramic grains that self-sharpen, offer both excellent stock removal and a cool grind, the Premium range will not discolor, or contaminate the material. Grits from 40 up to 120 allows for a versatile choice to suit almost any application. The Premium range also includes a flap disc suitable for non-ferrous metals.

Apart from cutting and grinding solutions, we also carry a range of coated and non-woven abrasives. Sanding belts can be manufactured for handheld machines, pedestal or floor machines, stroke sanders as well as wide belt machines. To achieve a brushed finish, opt for finer grit belts.

Our non-woven products are composed of abrasive grains that are fused to a three-dimensional support of nylon fibres. Uniform distribution of the abrasive combined with the softness of the material ensures a constant and consistent finish throughout the working process and product’s lifetime to suit applications for a mirror, satin, or a brushed finish.

When blending the scratch pattern with our non-woven range of products, you will achieve a matte finish which can then be reworked to a mirror finish by using products from our range of light de-burring wheels, buffs, mops, and soaps.

Whatever your cutting, grinding or finishing requirement, we offer a total customised solution to suit your stainless-steel need.

Grinding Techniques – Your application, Our solution.

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

Grinding Techniques – Cost effective partner to the Foundry Industry

In most foundries, grinding wheel costs can vary immensely per ton of castings poured.

foundry_blog

This figure may vary from one foundry to another depending on the metal or alloy, size of casting, number and size of gates and risers, and on the type of equipment used—swing frame, floor stand or portable. Part of the cost involves wheels that may be used to notch or cut off gates and risers, but this article will concentrate on the wheels used for the snagging operation.

The grinding wheel can affect wheel costs as well as production rates. One major contributing factor to high grinding costs may be the use of the lowest priced grinding wheel obtainable. While this buying policy does offer the lowest wheel cost, it can ultimately be more expensive in both yearly purchases and labour costs. Furthermore, the cheapest wheel may also reflect inconsistent quality, which could result in a variation of grinding wheel performance from wheel to wheel and from order to order.

In order to extend longevity of the wheel with the main objective of a lower wheel cost, a wheel that is actually too hard for the application at hand is often used. The loss in the material removal rate and operator efficiency therefore offsets the costs of the wheel savings, as many tests have proved conclusively.

Using a too soft wheel, on the other hand, while contributing to a happier operator, will most certainly increase the total wheel consumption. Management may now ask how all these factors should be evaluated.

Some foundries measure grinding wheel efficiency in terms of the amount of metal removed versus the amount of grinding wheel used. Others may measure the grinding wheel cost per kg of metal removed. Both these methods may result in a two-dimensional view where a three-dimensional view with grinding time added will in most instances supply a better result.

In some instances, foundries do not realize how important wheel selection can be, relying only on operator opinion for the best wheel to use, without measuring wheel consumption or metal removed. Although this may seem like a simple solution, it is not likely to result in determining the efficient grinding wheel, or the lowest grinding cost. Operators most likely will tend to prefer a soft fast cutting wheel.

The above-mentioned approaches will most likely provide a very high ratio of metal removed to wheel wear resulting in a low production rate, or high productivity but with a relatively high wheel consumption. The ultimate aim is to strike a happy medium between rate of metal removed and wheel consumption.

The missing third dimension in these approaches to wheel efficiency and grinding costs is the time element. Labour and overhead costs in most cases contribute more than the wheel cost in determining the total grinding cost. The only accurate way to determine a fettling operation cost is to determine the weight of metal removed, weight of wheel used, and the total contact grinding time of the test. Contact time rather than total elapsed time is important as it is not subject to operator effort. Accurate measurement of the contact grinding time per casting or per test run is of utmost importance.

With contact grinding time readily available, accurate means of determining the weight of metal removed while grinding must also be obtained. The castings selected for test, after chipping and sorting of scrap, should be weighed before and after grinding. Larger castings should be weighed individually and small castings can be weighed by skid load. To ensure accurate grinding wheel cost information, the wheel should be weighed at full and then at stub diameter. The difference represents the weight of usable abrasive consumed during the test.

The castings selected for the test should all be of the same metal or alloy, and approximately the same size and shape. In reality, these last two conditions are not always possible. It is then that the value of determining contact time becomes even more relevant. It helps to balance out the effect of just such variables in the work pieces. Furthermore, when a wheel is used by more than one operator, using contact time in calculating the wheel efficiency and costs helps to eliminate variables in operator technique and operator opinion of a wheel.

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

Preparing Ferrous Metals for Painting

Painting is the process of coating a material with a protective layer in order to reduce oxidation and extend the material’s usable life and or applying a coating for decorative purposes.

PREPARING-FERROUS-METALS-FOR-PAINTING

When you are painting IBR sheeting, palisade fencing or anything else in and around your home, it is of utmost importance to follow the correct steps and techniques to ensure the quality and longevity of your coating.

Ferrous metals either contain, or are derived from iron. Examples of ferrous metals would be fabricated sheet steel and wrought iron – all prone to rust. Rusting can start very rapidly when unprotected ferrous metals are exposed to elements of nature. It is of utmost importance to stop and remove any rusting that has begun to guarantee that there is no compromise to the appearance and longevity of the paint job and the material itself.

Surface preparation is considered one of the most important factors when it comes to the coating quality of your end product and vital to the success of any paint job. Removing any visible rust and peeling paint would be the very first step when preparing any ferrous metal surface for painting either by wiping the surface with a cloth or brushing with a soft bristle brush. In some cases, with a more abrasive material would be necessary whereafter the surface can be scrubbed with a water-based degreaser and then rinsed off with clean water. Depending on the size of the job on hand and the severity of the imperfections on your surface this can be achieved by the use of various abrasive products. Hand or power tools might be used dependent on what you have in your toolbox.

Great results can be achieved by hand sanding with wet or dry abrasive sheets, starting with a coarser grit size for aggressive stock removal of imperfections working towards finer grit increments until the desired surface finish is achieved. When it comes to working with a power tool, wire brushes, abrasive sanding discs and non-woven rough cleaning products are all ideal for this application.

Always remember to wear the correct personal protective equipment which should include eye protection and a good quality dust mask. New ferrous metal surfaces where imperfections might not be visible to the naked eye should also be prepared adequately to avoid a premature failure of your paint job. New metal often has mill scale or oil on it or small amounts of rust not yet visible. The timing of your preparation and applying your primer and topcoat is of utmost importance. If the prepared surface is exposed for as little as a day or two the surface will have to be prepared again. Always be sure to apply a quality rust-inhibitive primer before applying your final coat.

Galvanized metal is iron or steel with a thin coating of zinc to prevent rusting. Galvanized metal is commonly used for gutters, downpipes and flashing. If the galvanized surface is new or weathered it should be washed and rinsed thoroughly before painting. This process cleans off any zinc chromate or residual oil that could have been left on the surface from the galvanizing process which otherwise can interfere with the adhesion of the paint.

On previously painted galvanized surfaces all rust and peeling paint should be removed with a wire brush, abrasive disc or non-woven abrasive product. Always try and avoid cutting through the layer of zinc galvanizing during this process. Always be sure to apply a quality rust-inhibitive primer before applying your final coat.

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

INNOVATIVE partner to the Foundry Industry

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.

blog_image

With the global Covid-19 pandemic significantly impacting the current economic climate we find ourselves in, many rely on price as a deciding factor when abrasives are considered and, in many cases, settle for entry level abrasives. This often results in a costly and time-consuming operation, as more abrasive products are required to complete the job due to the lower stock removal from the product, which in turn, leads to operator fatigue. It is therefore of utmost importance to consider the type of casting, machinery and abrasive products used in combination when fettling castings.

With the correct combination of abrasive grains, there are numerous advantages. Instead of spending hours to a full day fettling a single casting, time can be cut down to just a few minutes leading to other benefits like saving on electricity, machine wear and tear as well as reduced operator fatigue.

When fettling a casting made out of Hard Chrome with an approximate riser of 50mm, if using an under-powered angle grinder, this could cause a significant increase in fettling time, resulting in the efficiency of the grinding disc being severely reduced. The slower the speed at which the grinding disc rotates, the softer it acts, taking much longer to chip away the material with every revolution due to the disc not attaining the grain in place for optimal performance.

To attain better results, there are a few options available:

Firstly, using an angle grinder of at least 2.6kW will help the disc not to lose peripheral speed when in operation, thus increasing the performance of the disc. Secondly switching to a higher product tier, like either the Superflex 230x7x22.2 ZA24R Premium containing Zirconium abrasive grains, or the Superflex 230x7x22.2 CA24Q-BF Premium Ceramic grinding disc containing added seeded gel. This alone, could significantly increase results.

In general, using abrasive products containing Zirconium grains rather than Aluminum Oxide grains usually prove much more efficient, as the Zirconium grains break down during application, exposing sharper cutting edges – perfectly suited to difficult alloys. In cases where optimum results are required, making use of the Ceramic grinding disc containing seeded gel would prove to be the ideal choice. Not only does the Ceramic disc offer a much tougher structured grain, but will, when put under pressure, break down in much smaller fragments exposing sharper cutting edges, which significantly increases the cutting rate and minimizes heat input into the work piece.

Cup stones are another possible solution for fettling requirements, as they have either a M14.2 or a 5/8 BSW thread, which saves time compared to changing grinding discs, as the cup is simply screwed onto either an angle grinder or a pneumatic grinder. Due to the design of the cup stone being flared (Type 11), grinding Hi-Chrome materials and specifically crusher balls are made easier to work around the shape of the ball’s circumference, preventing unnecessary deep grind marks compared to that of grinding discs when grounding away the risers.

Grinding Techniques have been manufacturing abrasives since 1981, with a Research and Development Team constantly testing, reviewing and introducing new products ranging from Aluminum Oxide, Silicon Carbide, Zirconium and Ceramic / Seeded gel grains. With our years of industry experience and partner to the Foundry Industry we are leaders in helping you choose the best solution for your application.

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

ANDOR – The PREFERRED PARTNER in Railway Maintenance

Railway technology has improved significantly over the centuries – starting with wooden rails firstly introduced in the early 1500’s moving on to cast iron plates fixed to the upper surface of wooden rails that increased durability and load-bearing by the Colebrook Company in the 1790’s to the late 1780’s, where L-shaped metal plates – better known as plateways were introduced.

blog_article_image

Through the years the advancement continued as it worked its way through all-iron edge rail and variations of cast-and-wrought iron. Today we make use of superior all-iron rail, with a high manganese content that allows for high wear-and-fracture resistance.

To keep up with increasing railway innovation, abrasive technology constantly has to adapt and change to meet the demanding task of grinding these superior rails.
Aluminium Oxide, Zirconia Alumina and Ceramic Alumina have become some of the latest raw materials to be mixed and bonded into various formulas for optimum performance during rail maintenance. As hard-wearing, durable rails are heat-treated with a maximum Carbon percentage of up to 0.82, and a maximum Manganese percentage of up to 1.7, it is of utmost importance to ensure a product is used for maintenance that not just deliver optimum results, but also ensure rails keep their durability throughout their lifetime.

Grinding Techniques carries a range of ANDOR grinding wheels specifically manufactured for railways that deliver fast stock removal, longevity and durability.
Our Research and Development Team are constantly testing and reviewing our products to ensure they deliver the best results, regardless of specific customer needs or harsh working conditions.

Rail transport in Australia is a vital aspect to the overall transport network. The Australian railway network consists of 36,064km (as of 2018) of track utilizing 3 types of gauges.
14 818 km of Standard Gauge, 15 625 km of Broad Gauge with the balance made up of Meter Gauge and Narrow Gauge. According to Wikipedia a total of 413.5 billion tonne kilometres of freight was moved by rail between 2015 and 2016. The only way to keep all of this railway in good operating condition and ensuring railway longevity, is regular railway grinding maintenance.

Effectively, this will eliminate multiple defects like Gage Corner Shelling (a progressive internal separation that can crack out), Spalling (localized degradation commonly found at the gage corner of the high rail), Side Wear (wearing at the side of the rail head which wears with the train wheels because of the interaction that can lead to profile change of the rails), Plastic Flow (also known as bodily deformation that results from high loading and tangential to the wheel/rail contact), Corrugation (uneven but regular corrugation shape of wear, either from elastic sliding or vibration) and Rolling Contact Fatigue (cracks in the rail head that occurs over time, which if not treated can propagate its way into the rail web, a precipitating factor of a rail break) when done regularly and efficiently.

When it comes to any and all railway grinding, Andor is the preferred rail maintenance partner. With several machine manufacturers used in railway maintenance, Grinding Techniques features the technology, capabilities, backup and inputs to produce some of the best quality abrasive products available on the market to suit all of the rail equipment grinding consumable requirements. The ANDOR range doesn’t only feature the most common shapes used in rail grinding, but also allow for wheels to be customised according to specific customer requirements.

Three most popular wheels are illustrated below with an indication of their positions on the rail during the grinding process.

A: Commonly used for reprofiling tracks, welding preparation of surfaces and grinding wells for finishing purposes is the ANDOR MP12 wheel. An organic resin bonded wheel with inserted nuts or 5/8” thread, that works in position A and B.

article_image

B: When it comes to grinding the lateral edges of the track, the organic resinoid bonded MC2 wheel gets the job done quickly and efficiently. Workable in the position indicated below of the track.

article_image

C: Used in web grinding to improve contact for welding purposes, the MS9 wheel works in the position C of the track in the below drawing.

article_image

In relation to the below drawing, ANDOR manufactures a range that includes all three these wheels.

article_image

Journey to the future by making Andor your best asset in railway grinding and join the evolution of railways.

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

Sanding Made Easy When It Comes to Power Tools

Sanders are one of the most frequently and extensively used power tools in Industrial workshops and DIY applications. Depending on how often they are used, it makes sense to choose a sander and abrasive product that suits you ergonomically. If you do a large variety of different types of sanding in your workshop for example surface sanding of large flat surfaces, edgework or molding and profile work, you will want to consider purchasing application specific sanders. Unless you are working in a high production environment using a sander for most of the day, a power sander will most likely last you for many years, if used with a quality abrasive product.

blog_article_image

One of the most common challenges faced when using a sander is the visible scratch pattern left behind on the material that has not been eliminated through sanding. This can normally be clearly seen as the visible swirl pattern and milling marks when looking at the surface finish. These surface marks can be eliminated by using high quality application specific engineered abrasives that have consistent uniform grain patterns guaranteeing a more consistent and uniform scratch pattern on your workpiece surface. Selecting the correct sequence of abrasive products and grit sizes to create the desired surface finish is also of utmost importance when sanding with a power tool. When sanding with a progressively finer array of grit sizes will produce a much more constant surface finish which will also eliminate excessively deep swirl and scratch marks created when forcing the sander down to work harder and more aggressively. One must always remember the power tool’s weight should be sufficient for achieving the best sanding results. Excessive pressure whilst sanding creates more heat and dust which promotes clogging that severely affects the lifespan of you abrasive.

The most effective way to keep your surface dust free, is to use a power tool with a dust extractor. This will not only save time when it comes to applying the final finish, but will also ensure minimal dust on your workpiece surface that has to be cleared. Power tools with dust extraction prolongs the life of your abrasive as there will be significantly less clogging.
Random Orbital Sanders, Sheet Orbital Sanders, Detail Sanders and Belt Sanders are some of the most commonly used power sanders used in workshops of a hobbyist or DIYer. Of these, Random Orbital Sanders are with reason the most popular and most frequently used universal power tool due to their effective stock removal capabilities on large surfaces and their ability to deliver a smooth consistent finish.

Their backing pads move in an orbital motion while at the same time moving in an eccentric (off-center) orbit motion. The result is an irregular scratch pattern of swirl marks that can be easily and quickly removed by hand sanding before applying your final finish. There are models available in different strokes per revolution depending on the task at hand. Increasing sanding speed and applying a little more downward pressure will generally increase the cutting power and help to decrease your sanding time. Keeping these benefits in mind, it is important to remember that this will increase the severity of the swirl marks. These power tools are normally available in 125mm & 150mm backing pads with a Velcro clamping system, with discs that are quick and easy to mount and remove. These sanders also normally include a dust extraction bag or canister while some will have a port for connecting to a dust extractor, which will provide the most superior dust extraction.

Sheet Sanders are also called orbital sanders. They generally have a pad that takes a half or one third of a normal sandpaper sheet that is 230 x 280mm. The backing pad normally runs in one direction only, removing material more slowly than Random Orbital Sanders. As a result, the scratch pattern is very consistent. For the best results in wood sanding the sander should be moved in the same direction of the grain of the wood whilst sanding. Some of these sanders take a PSA (pressure sensitive adhesive) or Velcro sheet of paper, but most use metal clamps for attaching standard sandpaper sheets you can cut to size or purchase pre-cut. The shape of the backing pad enables them to sand close to the inside of corners, and their compact size makes them easy to control and ideal for sanding narrow surfaces such as table legs and drawer parts.

Detail Sanders come in a few configurations. These power tools are similar to sheet sanders but have triangular pads. Often also called Mouse Sanders, they are typically used by DIYers and hobby woodworkers. These power tools are ideal for reaching the tight hard to reach areas that are inaccessible to conventional sanders. The sandpaper used on these sanders is normally Velcro backed for quick and easy mounting and removal.

When removing large amounts of material very quickly, Belt Sanders are ideal and the most effective. This power tool is suitable for leveling wide and long surfaces or shaping larger curves. Being so universal, this remains a popular tool of choice for carpenters, flooring and cabinet installers, deck builders and the like. Sanding belts ranging from 60x400mm up to 110x610mm are available in various grit sizes and suit most belt sanders on the market.

Whatever your tool of choice, achieving the perfect finish is certainly made possible by using quality product options available in the market.

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

Blending welds successfully

A weld occurs when metal parts are fused together using heat and a filler material, various welding processes exist like MIG/ MAG, TIG or MMA/ STICK welding.

blog_article_image

Depending on the skill of the welder, the need may arise for cleaning and blending of the weld bead after welding.

There are several products on the market to assist in achieving the desired finish. A wide range of abrasive discs, points, burrs, and wheels are available depending on the application. Selecting the correct abrasive consumable will always depend on the available power tool.

When selecting an abrasive product, always use a product for the power tool you feel comfortable with and select a product that is manufactured specifically for the material you intend working on. This will limit excessive heat or discolouration and ensure that the material is not contaminated, reducing the possibility of further welds being required.

In many cases an angle grinding disc would be suitable if stock removal is required, but to achieve both a high-quality finish and stock removal, an abrasive flap disc should be considered.
If your tool is limited to a hand-held drill, spindle mounted flap wheels would be a suitable alternative. If you opt for Tungsten carbide burrs or abrasive Mounted points, you’ll have finer control when finishing small welded areas especially when working in difficult to reach areas, however it needs to be noted that these products operate at higher speeds and will require a die-or-pencil grinder as they do not work on a hand-held drill. Specialist abrasive products like dual purpose cut-and-grind discs are also available making both cutting and grinding applications possible with one product.

When making use of coated products to blend welds, depending on the thickness and size, care should be taken to start with the finest possible grain if a good surface condition is required. The next coarsest grain should be selected only if the stock removal rate is insufficient. This reduces the steps in achieving the desired finish.

When it comes to the decision of what finish would be best, one needs to consider the base type material used and determine if the welds need to be removed. In some cases where the welds are not visible or being painted, they need not be removed.

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

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.

blog_article_image

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.

blog_article_image

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.

blog_article_image

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.

MUST-HAVE-ABRASIVES-FOR-YOUR-TOOLBOX

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.

WHEN-TOLERANCE-IS-KEY-IT-IS-VITAL-TO-CHOOSE-THE-CORRECT-PARTNER-FOR-YOUR-PRECISION-GRINDING-OPERATIONS

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.

blog_article_image

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.