How to choose different abrasives to save cost and time

Common Abrasive Grains and Their Differences

There are several factors to consider in choosing the right abrasive product for the application so your operations can get more done in less time — and with less labor. It’s important to match the rated speed and size of the grinder to the rated speed and size of the cutoff wheel or grinding wheel. Understanding the material and how it acts during cutting and grinding will provide direction regarding the optimal abrasive grain and product design for a given application. The base material thickness and removal rate needed also play key roles in choosing the right product design and grain.

Different abrasive grains provide different levels of performance due to their physical characteristics. Grain toughness speaks to durability while a sharper, less tough shape may help cut hard-to-grind material better than a durable, blocky shape. Below are some grains commonly used for resin-bonded abrasives.

· Ceramic: Abrasives made with ceramic grains have a higher acquisition cost. Ceramic abrasives deliver the highest performance and help work get done faster, often making them the best value. They provide more efficient cutting action and generate less heat in the grind zone, which greatly benefits productivity. In addition, more efficient grinding generates less friction and vibration for improved operator comfort, which also equals more productivity in the shop. These abrasives work especially well on metals that are more difficult to grind, including stainless steel and heat-treated steels.

· Zirconia: A zirconia blend abrasive is durable and provides long product life. This grain is the workhorse of the abrasives industry, performing well in high-pressure applications where other grains dull quickly. It can be used on mild steel and will hold up to rough cutting and heavy, high-pressure, high-horsepower applications that produce a lot of heat. Avoid using a hard zirconia grain on aluminum, which is a softer metal. The bond is too hard for aluminum and the abrasive will load easily.

· Aluminum oxide: An AO blend abrasive will efficiently cut soft aluminums without loading or glazing. This grain is also a good choice for mild steel, providing value, a fast cut rate and consistent performance.

· Silicon carbide: This grain works well for non-ferrous applications, such as brass or aluminum.

Testing Different Grain Types

A product conversion can yield significant results — even without jumping to the highest-quality abrasive available. For example, going from an inexpensive, baseline aluminum oxide wheel to a higher-quality zirconia product is a good start.

Ceramic is often the highest-performing abrasive grain. Operations currently using aluminum oxide or zirconia should consider testing a ceramic abrasive to see what results they can attain, especially if they are looking to get more work done in the face of labor shortages. These products can help minimize bottlenecks in the operation.

Companies can conduct a cost analysis to determine cut-off wheel and grinding wheel costs, a process that is made easier by working with abrasives experts. The process doesn’t have to interrupt production or take up time at facilities. Bringing in abrasives experts to lead this process and test products removes the burden from manufacturing operations. Abrasives experts bring extensive product knowledge and industry experience. This allows them to study the data and quickly identify the best abrasive for the specific situation while considering all possible factors, including material, application, tools, how the product is being used and more.

Through real-life testing, users can compare product life, cycle times, cutting rate, cutting index, material costs (initial wheel price) and labor costs between different wheels used on the same materials and same tools with the same parameters.

Addressing Labor Challenges with the Right Abrasives

When an operation has a smaller pool of skilled labor to get work done, efficiencies must be found elsewhere to make up for it. Using the fastest-cutting and most efficient off-hand abrasive tools for metal preparation, cutting and finishing can help save significant time and money.

Choosing the best abrasives for your application can be difficult but leveraging the expertise of your local manufacturing representative can help you get the answers you need — even in just a single site visit. Bringing in a manufacturing rep can help operations plan for current and future projects. Additionally, spending time with your local manufacturing reps will keep you up to date on new technology designed to optimize your projects and applications.