The importance of choosing the correct abrasive mineral for coated applications

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The castings and foundry industry plays a pivotal role in the manufacturing and production of essential components for various sectors ranging from automotive to aerospace. To ensure quality, functionality and the desired finish of the final product, the fettling process is critical, notes specialised grinding products supplier Grinding Techniques.

Fettling applications involve the removal of unwanted material, such as excess metal, burrs, or casting defects from the surface to achieve precise dimensions and a smooth finish.

Coated abrasive products, particularly in the form of sanding belts, are indispensable tools in this process. Not only do they maintain their cutting edge throughout their lifespan, reducing the need for rework or touch-ups, but they also offer efficiency, precision and versatility.

With the abrasive minerals embedded in the sanding belts, high material removal rates and reduced processing times are enabled, while the application offers precise control over the stock removal application.

These minerals can vary widely in their composition, each suited for specific applications based on hardness, shape and cutting properties.

Offering grinding, deburring and blending operations, while adapting to different shapes and contours of cast components, sanding belts can be manufactured in almost any grain, suited for various materials including ferrous and non-ferrous metals.

Known for its toughness and versatility, alumina oxide is widely used in both woodworking and metalworking applications, and is effective for grinding and finishing operations owing to its hardness and ability to maintain sharp edges. Zirconia alumina, which combines the toughness of alumina oxide with the performance of zirconia, is an exceptional and durable mineral, often used for heavy stock removal and grinding of metals. For applications on non-ferrous metals, and other materials with low tensile strength such as brass, aluminium and titanium, and particularly where a fine finish is required, Grinding Techniques recommend using coated abrasive manufactured with silicon carbide.

Owing to recent developments in ceramic abrasive grains, it is now possible to manufacture abrasives with superior cutting performance and longer lifespan. Abrasives manufactured with ceramic grain will offer the ultimate in stock removal, making them ideal for demanding applications in fettling operations.

However, to ensure an optimised fettling operation, any selection of sanding belts should start with the consideration of the  hardness of the casting material, as this is key to achieve effective stock removal  without causing damage or excessive wear to the abrasive belt.

The grit size determines the surface finish and material removal rate where coarser grits are used for rapid material removal, and finer grits are employed for achieving smooth finishes.

Backing material of sanding belts vary from cloth and paper to fibre and polyester film, each posing its own properties in terms of flexibility and durability. Flexible backings are suitable for contours and irregular surfaces, while rigid backings provide stability for heavy grinding applications.

Sanding belts are also available with special coatings, such as stearates, or grinding aids which reduce heat build-up and improve abrasive performance, particularly when working with heat-sensitive materials.

The field of coated abrasive technology continues to advance, driven by innovations in abrasive mineral formulations and backing materials, incorporating features such as varying grit sequences or special backings to optimise performance in different stages of fettling.

Grinding Techniques stock a wide range of coated abrasives to optimise any fettling operation.

As a local supplier, it is able to assist with a custom abrasive solution to customer-specific applications.

Partner with Grinding Techniques today and secure your supply.

For more on our range or product offering, contact us on +27 11 271 6400| info@grindtech.com| www.grindtech.com