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Flexovit Abrasives Training


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Flexovit Abrasives Training

  1. 1. 1-800-689-FLEX flexovitabrasives.comFlexovit Overview
  2. 2. 1-800-689-FLEX Topics1. Introduction to Flexovit2. Abrasives Overview, with Focus on Reinforced Resin Bonded3. Introduction to Flexovit Product Tiers4. Grinding and Cutoff Wheel Safety
  3. 3. 1-800-689-FLEX Corporate Offices & Manufacturing Facility Located in Angola, New York• 100,000 Square Foot manufacturing facility.• Most technologically-advanced grinding wheel manufacturer in North America.
  4. 4. 1-800-689-FLEX Manufacturing Facility• Flexovit manufactures the entirebonded abrasive wheel including thedie-cast spin-on hubs, andfiberglass reinforcements.
  5. 5. 1-800-689-FLEX Product Testing Completed at our factory...• ISO 9001:2008 Certified• On-Site Testing Lab• On-Site R&D Lab
  6. 6. 1-800-689-FLEX Topics1. Introduction to Flexovit2. Abrasives Overview- with Focus on Reinforced Resin Bonded3. Introduction to Flexovit Product Tiers4. Grinding and Cutoff Wheel Safety
  7. 7. 1-800-689-FLEX Abrasives Overview - with Focus on Reinforced Resin BondedThe four main abrasive systems are: Bonded Coated Abrasives Abrasives Non Woven Superabrasives Abrasives
  8. 8. 1-800-689-FLEX Bonded Abrasive WheelsResin BondThe resin bond is tough and resilient.Resin bond wheels may also bereinforced with fiberglass meshfor added strength.Because of their strengththey are recommendedfor thin cutoff wheels, andfor grinding wheels that aresubjected to severe lateralpressure or shock, includingwheels used on portable power tools.Vitrified Bond Rubber BondIs a rigid bond, somewhat fragile, used Composed of synthetic or natural rubber. It is usedprimarily for precision grinding and finishing extensively on thin cutoff wheels for burr-free cuts,operations. It is not recommended for surface as well as regulating wheels on centerlessspeeds over 6,500 feet per minute. Vitrified grinders. These wheels are relatively fragile, andwheels are typically used on stationary therefore used on stationary machines with a fixedmachines. cutting plane and securely clamped workpiece.
  9. 9. 1-800-689-FLEX Resin Bonded Abrasive Wheels - How a Grinding Wheel is Made: ComponentsAbrasive Resin Fiberglass Grains Bonds ReinforcingArbor Wheel Spin-onRing Label Hub
  10. 10. 1-800-689-FLEX Resin Bonded Abrasive Wheels - How a Grinding Wheel is Made: GrainsThe four main types of abrasive grains used in Resin Bonded wheels are: Aluminum Silicon Oxide Zirconia Carbide Alumina Ceramic• Tough, blocky, wedge shaped • Extremely hard andgrain. sharp, but fractures more • Very tough, sharp, and dense. • Sharp microcrystalline easily than aluminum grain-cuts aggressively oxide. • Lends itself to higher under light to moderate• Performs well on carbon steel, temperatures and pressure. • Performs well on Caststainless steel and aluminum. heavier pressures Iron, Nonferrous Metals present in high-stock • Its quick cutting (Aluminum) and Non- removal applications capability makes it Metallic materials including suitable for grinding Concrete, brick, marble and stainless steel, titanium, glass. and high-nickel alloys.
  11. 11. 1-800-689-FLEX Resin Bonded Abrasive Wheels - How a Grinding Wheel is Made: GrainsDetermining Grit Size:Abrasive grains are sized by passing them over screens having a certain number of openings per linearinch. The number of openings per linear inch in the screen through which the particles just passdetermines the grit size. Resin bonded wheels typically use relatively coarse grits such as 24 and 36. Coarse Grit Size (30 Grit) Fine Grit Size (108 Grit)
  12. 12. 1-800-689-FLEX Resin Bonded Abrasive Wheels - How a Grinding Wheel is Made: Fiberglass ReinforcingHigh tensile fiberglass mesh is incorporated in the wheel for more durability. Grinding Matrix Backing Matrix 7 x 1/4 x 5/8-11 Triple-Layered fiberglass-Reinforced, Depressed-Center Grinding Wheel, Product Code A5356H
  13. 13. 1-800-689-FLEX Resin Bonded Abrasive Wheels - Understanding the Specification (Spec) ex. A30S 1.) Abrasive Grain 2.) Grit Size 3.) Grade/Hardness* A 30 S A = Aluminum Oxide 16 Coarse M SoftC = Silicon Carbide 30 Medium R Harder S ZA = Zirconia Alumina 60 Fine T HarderCG = Ceramic 120 Very Fine Z Hardest*Each grain of abrasives is joined to other grains by a bond material. The strength with which this bond hold the grains isknown as the grade or hardness of the wheel. Grade or hardness is expressed by a letter of the alphabet, with A being thesoftest and Z indicating the hardest bond.
  14. 14. 1-800-689-FLEX Resin Bonded Abrasive Wheels - How a Grinding Wheel WorksThe Cutting Tool Principle: Abrasive • Abrasive grain begins to • Other abrasive grains • Before the edges of theWheel Grains Workpiece cut chips from the are revealed as the wheel abrasive grain become workpiece’s surface. As it bond wears from contact too dull, they are tornBond does, the grain begins to with the workpiece. away from the wheel wear down. It fractures, bond, allowing other presenting a new sharp abrasive grains to come edge. into play.
  15. 15. 1-800-689-FLEX Resin Bonded Abrasive Wheels - Wheel Construction: HardbakFlexovit’s Hardbak wheel design boosts productivity and safety on the shop floor by eliminating prematureshedding and shearing of grain from the leading edge of the grinding face.The Hardbak design incorporatesa thin layer of relatively fine abrasivegrain and hard bond sandwichedbetween two full diameters offiberglass. The remainder of thewheel is comprised of two thicklayers of coarse grit and bond.These are separated by a third fulldiameter of fiberglass reinforcing.The leading edge of the grinding faceis now resistant to grain shedding orchipping, allowing the coarser grain tofully do its work and eliminate the Flexovit Wheel Competitor Wheelhazard of flying chunks of abrasive. with Hardbak without HardbakHardbak is incorporated in the design of all Flexovit 7” and 9” depressed center grinding wheels as well as inall premium (Flexon) and semi-premium (Metalhog) depressed center grinding wheels.
  16. 16. 1-800-689-FLEX Resin Bonded Abrasive Wheels Wheel Types - ReinforcedType 27: Depressed-Center Wheels Grinding wheels are designed to be used at a 30 degree angle from the workpiece. Cutoff wheels are designed to be used at a 90 degree angle to the workpiece and may be used for flush cutting.Type 28: Saucer Shaped Wheels This wheel operates at a wider contact area than the Type 27, resulting sometimes in a better finish, but it also offers more aggressive stock removal. It can be used at shallower angles, 10 to 15 degrees from workpiece.Type 29: Flared Up (Found in Zircotex/ZircoMax Flap Discs & Flexcel Wheels) Fiberglass reinforced depressed center product, featuring a flared profile with a convex surface on one side. This shape allows a wide contact area, and can be used at a greater variety of angles, anywhere from 10 to 30 degrees.Type 1: Flat A round, flat wheel with a hole in the middle. These wheels are designed for grinding or cutting on the periphery, or edge, of the wheel only. They may or may not be fiberglass reinforced.
  17. 17. 1-800-689-FLEX Resin Bonded Abrasive Wheels Wheel Types - Non ReinforcedType 1: Flat - Bench Grinder Wheels A round, flat wheel with a hole in the middle. These wheels are designed for grinding or cutting on the periphery, or edge, of the wheel only.Type 11: Flaring Cup Wheels - Also called: ‘Cup Rocks’ or ‘Cupstones’ Resin bonded cup wheels are used for heavy stock removal applications. Unlike depressed center wheels, these wheels are not fiberglass reinforced.Type 16,17 Plugs & Cones18 & 18R: These are designed for difficult to reach places, such as odd-shaped castings. Good for internal grinding as well.
  18. 18. 1-800-689-FLEX Topics1. Introduction to Flexovit2. Abrasives Overview- with Focus on Reinforced Resin Bonded3. Introduction to Flexovit Product Tiers4. Grinding and Cutoff Wheel Safety
  19. 19. 1-800-689-FLEX flexovitabrasives.comFlexovit Product Tiers Product Offerings Depressed Center Wheels, Cup Wheels, Plugs & Cones, Bench Grinder Wheels, Mounted Points, Die Grinder Wheels, Cutoff Wheels, Coated Abrasive Products, Non- Woven Abrasive Products, Carbide Burs, & Wire Brushes. Depressed Center Wheels, Circular Saw Wheels, & Stationary Saw Wheels Depressed Center Grinding, Cutoff and Combination Wheels, Cup Wheels, Die Grinder Wheels, Cutoff Wheels & Resin Fiber Sanding Discs. Depressed Center Wheels, Cutoff Wheels, Resin Fiber Sanding Discs Thin Cutoff Wheels & Depressed Center Thin Cutoff Wheels Semi-Flexible Grinding / Blending / Finishing Discs Super Flap Discs High Density Super Flap Discs
  20. 20. 1-800-689-FLEX Flexovit Product Tiers DescriptionsThe wheels are the hardest working aluminum oxide wheels available. Precision made to ensure smoothand safe operation, these versatile products set the standard for fast material removal, and ruggedreliability and long life.Metalhog wheels incorporate a blend of premium, semi-premium, and standard abrasive grains withcustom bond systems. This produces an extremely aggressive wheel, without sacrificing wheel life.Offering a combination of premium Zirconia and Ceramic grains with advanced bond systems, thesewheels deliver the highest productivity.Specially designed to optimize performance on a particular material. Flexovit Specialist wheels areavailable for a variety of materials including; stainless steel, aluminum and concrete/masonry.Flexovit’s Razorblade series of thin cutoff wheels for angle grinders are an indispensable tool for themetalworker in both production and maintenance applications. Choose from 5 versatile specs dependingon the job requirement. Available in Type 1 as well as Type 27.These semi-flexible wheels remove material like depressed center wheel, yet blend and finish like a resinfiber disc. Flexs to contoured surfaces delivering a smooth finish without gouging.Extremely productive & efficient. Delivers twice the removal rate as ourIdeal for high production grinding, conventional Zircotex discs. Providesblending , deburring and finishing, it extremely long life and is our most productiperforms well on a variety of flap disc.materials.
  21. 21. 1-800-689-FLEX Topics1. Introduction to Flexovit2. Abrasives Overview- with Focus on Reinforced Resin Bonded3. Introduction to Flexovit Product Tiers4. Grinding and Cutoff Wheel Safety
  22. 22. 1-800-689-FLEX Who’s responsibility is safety?Machine Builder Wheel Manufacturer User
  23. 23. 1-800-689-FLEX Machine Builder The machine builder must make certain at the time of manufacture that the machine is of suitable design and properly guarded for the operation.Machine must be adequately guarded. Wheels can only be used on machines with safety guards that meet A.N.S.I. and O.S.H.A. specifications. Generally, a safety guard should enclose one-half of the wheel.MACHINE MUST HAVE PROPER FLANGES. Wheels can only be used between flanges mounted in accordance with A.N.S.I. specifications. Generally, flanges should be at least one-third the diameter of the wheel. Flanges should be kept in good repair and must be checked periodically for flatness, burrs or wear.MACHINE SHOULD BE WELL MAINTAINED. Wheels can only be used on machines regularly maintained by qualified personnel including periodic check of free running spindle speed (RPM).
  24. 24. 1-800-689-FLEX flexovitabrasives.comWheel ManufacturerThe wheel manufacturer must make certain that the wheels are manufactured to meet orexceed specification and have been tested in accordance with the ANSI standard B7.1- 2000safety requirements for the use care and protection of abrasive wheels and are marked withthe maximum operating speed as well as all necessary safety information.
  25. 25. 1-800-689-FLEX flexovitabrasives.comFeatures of aFlexovit WheelLabel
  26. 26. 1-800-689-FLEX Wheel ManufacturerAs we covered earlier, grinding wheels are made of thousands of small abrasive grainsthat have been bonded together using an organic resin compound. The bond must bestrong enough to hold the abrasive grains in place, yet friable enough to release dullgrain and expose fresh cutting points. (Friable refers to the property that makes the abrasivecapable of breaking down during the grinding process.) An unbreakable wheel simply would not grind. Fiberglass reinforcements of varying sizes and mesh, are used to strengthen the wheel. The material must first be coated with a resin to facilitate proper bonding to the abrasive matrix. The resin holds the wheel together. Poor quality resins can cause quick wear or wheel Fiberglass disintegration. Reinforcing Abrasive Resin Grains Bonds
  27. 27. 1-800-689-FLEX UserThe user is responsible for the proper handling,storage and inspection of grinding wheels afterreceiving the product.The user must maintain the equipment in safeoperating condition at all times. This includesperiodic speed checks of the equipment.All operating personnel must be instructed in thesafe use of their particular equipment. It isimperative they use the proper wheel for themachine and they must be sure the maximumrated machine speed DOES NOT exceed that ofthe wheel.Protection of operating personnel, as well asthose in adjacent areas, must be maintained at alltimes. It is the users responsibility to use andmaintain guards and other protective devices.
  28. 28. 1-800-689-FLEX User - Handling and StorageSuitable racks, bins drawers, pins or boxes shall be provided to store the various types of wheels.Depressed center wheels -should be stored flat or hung on pins.Cutoff wheels -should be stored flat. Do not stand them on their edgeas they are subject to warping.Bench and pedestal wheels -should be stored flat or standing on theiredge and each should be stored in a protective corrugated sleeve.Wheels should NOT be stored/subject to (causes of bond degradation):a) Water or other solventsb) Any temperature or humidity condition that causes condensation on If a grinding wheel has been or isthe wheels suspected of having been damaged,c) Freezing temperatures- special attention should be taken for wheels DO NOT USE IT.stored in mobile storage areas.
  29. 29. 1-800-689-FLEX User - MachineUSE PROPER FLANGES Both flanges, of any type, between which a wheel is mounted, should be of the same diameter and have equal bearing surfaces. Depressed center wheels, over 7” in diameter, should have a CP50 adapter. Check all flanges for wear and deflection.DO NOT OVER TIGHTEN Please tighten the wheel snugly! Over tightening causes several problems. It can bend the flanges by crushing them. It can also set up dangerous stresses in the wheel, which when centrifugal force is introduced, can cause the wheel to fail.USE CORRECT MACHINE FOR WHEEL Always make sure you have the proper machine for the wheel you are using. DO NOT USE A DEPRESSED CENTER WHEEL ON A PISTOL GRIP SANDER. Always check wheel speeds before mounting!
  30. 30. 1-800-689-FLEX User - MountingINSPECT WHEELS Visually inspect all wheels before mounting. Also inspect the packaging. If the wheel or packaging show any evidence of abuse, please do not mount them. Defects such as broken wheels, chips and gouges can be detected visually. Cracks in abrasive wheels are frequently not visible to the naked eye.To test for cracks in a vitrified wheel (bench or pedestal), administer a ring test.For organic bonded wheels (depressed center or cutoff), use proper start up procedures. (see ANSI 9.8 pg 111)CHECK SPEEDS Always compare maximum wheel and machine speed. The machine speed must be the lesser of the two.
  31. 31. 1-800-689-FLEX User - MountingUSE PROPER GUARDS Please use a guard! If breakage of abrasive wheels could be prevented, there would be no need for a guard. Conversely, if all machines could be completely guarded there would be no cause for worry about wheel breakage. However, both must be considered. Everything must be done to prevent wheel breakage and proper guards must be used. When using a grinding or cutting wheel ensure that the machine guard is positioned between the wheel and the operator.CHECK MACHINE SPEED Air tools should be checked every 20 hours or once per week. Electric tools should be tested monthly. All tools should be tested after repair or maintenance.
  32. 32. 1-800-689-FLEX User - Use and OperationSAFETY WEAR Proper eye and body protection not only makes good sense, it is the law in parts of our country. Glasses, gloves, goggles, shields and ear protection…. Whatever you can practically handle. Keep in mind, The peripheral speed of a 7” grinding wheel equals That of a .38 caliber bullet. Even a small piece of debris Is extremely dangerous.START UP When starting any grinding wheel, whether new or used, stay away from it! If it is a portable application, start the wheel with the rotation turning away from you or in a protected area. If it is a stationary application, stand off to on side when you start up.
  33. 33. 1-800-689-FLEX Use and Operation - Proper UseAll wheels have a particular application.Please use the wheel for what it was designed.Grinding Notching Smoothing
  34. 34. 1-800-689-FLEX Use and Operation - Common Misuses Deburring or beveling on the side of a type 1 cutoff wheel. This will sheer reinforcing that will cause premature failure when the wheel is subject to heavy cutting.Too shallow a grinding angle with type 27depressed center wheels causing an underminingof the reinforcing. This sets up for wheel failurewhen aggressive grinding pressure is introducedonto the wheel.Improperly tightened flanges on a large diameter cutoff wheel. Looseflanges spin against the wheel rather than supporting the wheel.This results in the arbor of the wheel failing.
  35. 35. 1-800-689-FLEX Observe These Safety Tips:1. Check all wheels for cracks or damage before use.2. Run the wheel in a protected area for one minute before grinding.3. Dont use wheels that have been dropped or otherwise damaged.4. Dont apply side pressure on any Type 1 straight wheel or Type 27 thin wheel.5. Dont use a grinding wheel with a rated speed less than that of the grinder.
  36. 36. 1-800-689-FLEX For Complete Safety Information please refer to theAmerican National Standards Book ANSI B7.1-2000
  37. 37. 1-800-689-FLEX flexovitabrasives.comWe Hope You Found This Presentation Informative. Thank You for Your Time.