Abrasive products coated in roll, disc and abrasive belt format are used in the main industrial sectors such as the automobile industry, the nautical ndustry, wood and varnishing, construction, and painting and decoration,among others.

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These abrasive materials are widely used and high consumption. In fact, we can affirm that in the majority of cases in which there has been a process of painting a surface, it has previously been subjected to a preparation process in which a coated abrasive product has been used.

Coated abrasive products are used in most surface preparation
processes for painting

Abrasive products: basic recommendations for choosing them

Because the market offers a multitude of options for abrasives transformed into rolls, abrasive discs and sanding bands, when choosing the most appropriate one, we must take into account some considerations:

Aspects to consider in the selection of sandpaper rolls

Accessibility to the work area, comfort and convenience for the user during the sanding operation, the type of material to be sanded, the sanding operation to be performed and the price variable are the main factors that condition the use of a type of sandpaper or other roll.

According to the type of support or backing material of the abrasive rolls wecan classify them into:

• Sandpaper rolls with flexible or rigid paper support. Optimal for any universal sanding and all kinds of metal, wood, varnish, resins and solid surface parts among others

• Sandpaper rolls with sponge paper support. Excellent for sanding profiles, moldings
  and curved surfaces

• Sandpaper rolls with velcro paper holders. Necessary for manual sanding with the help of coves and claws.

• Sandpaper roll with flexible, semi-flexible or rigid fabric support. Use for universal sanding of all types of materials, in which the performance of the abrasive takes priority over the final finish.

• Sandpaper rolls of non-woven fiber (scotch). Employees for surface shading.Abrasive products coated in roll, disc and abrasive belt format are used in the main industrial sectors such as the automobile industry, the nautical industry, wood and varnishing, construction, and painting and decoration, among others.

• Rolls of steel wool sandpaper. Used to achieve an excellent finish on varnished and difficult to access surfaces, which in turn will be finished in high gloss.

Aspects to consider when choosing discs and sheets

1 Format of the abrasive disc:

When choosing the abrasive disc we must take into account:

• The type of fastening of the disc to the plate, among which are:the velcro system, the self-adhesive system or the system without fixing by the support part.

• The outer diameter and the number of holes. Variables that must match the diameter of the plate and the number of holes in it.

2. Types of operation to perform.

• Coarse sanding of surfaces (grains 40, 60 and 80) corresponds to discs with a support of rigid paper or polyester film.

• Intermediate sanding of the surface (grains 100, 120, 150, and 180): it corresponds to discs with support on semi-rigid or flexible paper depending on the needs of adaptation to the surface that we are going to sand.

• Fine sanding (grains 220 to 600) we will opt for discs with a flexible paper backing or polyester film.

• Finishing sanding (grains from 600 to ). In this case, we will need sponge-backed discs or polyester film.

3. Embossing level: type of material to be sanded

In this case we can speak of two clearly differentiated types of materials:

• Embossing materials: for which we have abrasive discs that have a spaced or semi-spaced distribution of the mineral, in addition to a layer of anti-embossing stearate.

• Slightly clogging materials: this time we will use abrasive discs with a semi-spaced or closed mineral distribution depending on the type of material to be sanded.

4. Hardness of the material to be sanded

• Hard and tough materials, such as steels or alloys. We must use abrasive discs with ceramic ore, compact ore or zirconium ore. On occasions in which the development of the work will be carried out in areas with high temperatures on the surface, we must opt &#;&#;for abrasive discs that contain a layer of active lubricant.

• Highly hard materials such as stone, glass or ceramic. In this case, we will use abrasive discs with silicon carbide ore.

• Materials with a medium or low hardness. Use abrasive discs with aluminum oxide mineral. Maybe you're interested: Wind turbine repair: how to rebuild damage to materials

How to choose custom abrasive bands

In this case, we will focus on wide bands, those whose measurements are greater than 600 mm and up to 1,600 mm.
These types of bands are used in the wood and varnished sector for sanding flat pieces.
When choosing an abrasive belt there are different variables to consider:

1. The appropriate mineral for the type of material we want to sand:

• Zirconium ore should be used to sand hardwoods in rough calibration or surface sanding operations.

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• Aluminum oxide is the most common mineral used for sanding wood, veneer and melamine, in any sanding operation.

• Silicon carbide ore is used to sand fiber boards, particle boards and solid surface
  plates.

• As for the sanding of primers, sealants and bottoms, it is possible to choose between the use of the aluminum oxide ore or silicon carbide, depending on the type of
  bottom and the sanding operation, although in general the silicon carbide is The most
  employed.
  2. The distribution of the mineral is linked to the level of embouchure and hardness that the sanded surface presents.
  Therefore, it is necessary to take this particularity into account when opting for one type of band or another.

• Distribution of spaced ore: use for sanding soft and/or resinous materials prone to rapid swelling of the abrasive belt.

• Distribution of semi-spaced ore, for sanding wood, veneers, melamines, as well as primers and sealants in varnishing.

• Closed ore distribution. Use on fiber boards and chipboard boards.

  3. Existence of stearates to reduce embossing and improve the level of finish.
  In this way, it is possible to choose between different types of bands:

• Bands without stearate, used for general sanding of wood, veneer, melamines and
  boards.

• Bands with stearate, used for sanding putties, bottoms and solid surface in general.

  4. Take into account whether the abrasive belt is antistatic or not.

  Since it is a feature especially relevant in the case of continuous sanding and varnishing lines, in which the pieces are sanded and immediately after they are anchored and finished.
  Although, the antistatic bands prevent the dust released from sanding from electrostatic energy and easily adhere to the piece before varnishing.

  5. Support used for abrasive tape.
  Keep in mind that the choice of the type of support is determined by the type of operation to
  be performed.

• Calibration and sanding operations use bands with rigid cotton fabric support, or cotton with polyester or polyester only if the aggressiveness of the calibration operation requires it.

• Coarse or intermediate sanding operations, which involve the use of bands with rigid
  paper support weight F which allows proper planning of the sanded surface.

• Fine sanding or finishing operations, use bands with semi-rigid paper support weight E
  that allows transmitting the flexibility and sanding pressure of the sanding units with
  sectioned skid group.

• Superfinishing sanding operations, use narrow belts with polyester film supports to
  achieve uniform sanding and free of emboss marks.

  To choose the appropriate abrasive bands we must consider the appropriate mineral, the level of embossment and surface hardness, the existence of stearates, if the band is antistatic and the support used for it

Why with Abracom

At Abracom we are highly specialized in the customized transformation of coated abrasive products for the industry: rolls, discs and abrasive bands. We have the specific abrasive for each material and sanding operation. We advise our clients to recommend the abrasive products that best suit their needs. Contact us and we will advise you.

So how do you choose the right abrasive for specific tasks? Glad you asked. Look at these tips and at the table here to make the right choices and use your grinding wheels and discs safely.
 

 

Right Choices Matter &#;What is the Right Choice for Your Operation?
Abrasive products come in various levels of performance, which Norton conveniently labels "good," "better" and "best."

Which should you choose? Your choice involves balancing the results you want with the cost you're willing or able to pay. If initial price is your primary consideration, choose good abrasives, but be aware that a lower purchase price up front may not end up being economical in the long run. When you're running high-productivity applications and have to keep initial abrasive prices in mind, it's time for better abrasives. Consider the best abrasive products when maximum productivity and lowest total cost are critical to your operation.

When testing abrasive products to determine the best solution for your operation, there are three objective measurements to consider; one of which must remain constant between products being tested.  These measurements are time, material removed, and product wear.  By holding one of these constant and measuring the other two, you can come up with an objective comparison between multiple products.  For example, you could grind for 10 minutes with each product, and measure how much material was removed and how much of the abrasive products were lost; this is often measured by weight.  Alternatively, you could run each product to the end of its life, while measuring how much material it removed, and how long it lasted.  Finally, you could remove a set amount of material while measuring the time and abrasive wear. Each business has unique priorities; following these test methods will allow you to select the right choice to meet yours.

 

Abrasive Selection Guide

Take a look at this chart when choosing an abrasive for welding and metal fabrication. Each application lists the relevant products in the order of best, better and good.

APPLICATIONABRASIVE PRODUCTSFORMULATIONS

Grinding down metals:

Cut-off applications:

• Cutting sheet metal
• Cutting, notching pipe

Cut-off wheels

1. Ceramic aluminum oxide and zirconia alumina blend for stainless and carbon steels, other ferrous and exotic metals
2. Zirconia alumina for stainless and carbon steels and other nonferrous metals
3. Aluminum oxide blend for carbon steels

Grinding:

• All weld grinding
• Pipe notching, beveling
• Heavy stock removal

Depressed center grinding wheels (24 or 36 grit)

1. Ceramic aluminum oxide and zirconia alumina blend for stainless steel and other ferrous metals
2. Mix of zirconia alumina and premium aluminum oxide grains for metals ranging from alloys and stainless steel to gray iron and non-ferrous metals
3. Aluminum oxide

Blending:

• Blending welds
• Medium to light stock removal

See-through fiber discs
(24 or 36 to 80 grit)

1. Ceramic alumina for stainless steel and other ferrous metals
2. Ceramic and zirconia blend for low pressure grinding of
   ferrous metals.
3. Zirconia alumina for ferrous and non-ferrous metals
4. Aluminum oxide for ferrous metals

• Blending welds
• Metal fabrication

See-through fiber discs
(24 or 36 to 80 grit)

1. Ceramic alumina for difficult-to-grind materials, including super alloys and hardened steel
2. Zirconia Alumina for fast stock removal and rough cutting applications
3. Aluminum oxide blending disc for a consistent finish
4. Aluminum oxide for general purpose applications

• Dimensioning and shaping
• Heavy stock removal

Coated abrasive cloth belts
(for bench stand grinders)

1. Ceramic alumina for hard-to-grind alloys
2. Zirconia alumina blend for exotic and heat-sensitive metals
3. Zirconia alumina for stainless steel
4. Aluminum oxide for general use and maintenance/repair operations.

Blending the surfaces:

• Deburring welds

Coated abrasive flap discs
(60 or 80 grit)

1. Ceramic alumina
2. Zirconia alumina blend
3. Aluminum oxide

• Light deburring and finishing

Resin fiber discs (80 to 120 grit)

1. Ceramic alumina
2. Zirconia alumina blend
3. Ceramic zirconia blend
4. Aluminum oxide

• Blending and leveling  (contours or flat surfaces)

Coated abrasive cloth discs
(80 to 120 grit)

1. Ceramic alumina for a broad range of nonferrous applications
2. Zirconia alumina for fast, cool cutting
3. Zirconia alumina for stainless steel
4. Aluminum oxide

• Blending
• Finishing
• Polishing

Cotton fiber depressed center
grinding wheels may be used for light stock removal and finishing in one operation (24 grit for blending; 36 grit for finishing)

1. Cotton fiber combined with abrasive and flexible bonding material is especially good for bronze, aluminum and thin sheet steel

• Blending welds
• Deburring

See-through fiber discs (60 to 120 grit for light deburring)

1. Ceramic alumina for difficult-to-grind materials
2. Aluminum oxide blending disc for a consistent finish
3. Aluminum oxide for general purpose applications

• Surface preparation
• Blending welds

Coated abrasive cloth belts
(120 grit)

1. Ceramic alumina
2. Zirconia alumina blend for exotic and heat-sensitive metals
3. Zirconia alumina blend for stainless steel
4. Aluminum oxide

• Blending welds

Coated abrasive flap wheels
(80 to 120 grit)

1. Ceramic alumina
2. Aluminum oxide

• Cleaning
• Polishing
• Blending scratch patterns

Non-woven discs specifically for surface finishing (Medium, 120 grit)

1. Aluminum oxide

Creating the final finish:

• Polishing
• Finishing

Non-woven, surface-finishing discs
(Medium, 120 grit, or fine, 320 grit)

1. Aluminum oxide

• Weld polishing
• Cleaning
• Finishing
• Blending weld areas on stainless steel

Surface-finishing convolute wheels
(Medium, 120 grit)

1. Silicon carbide

• Final blending
• Touch-up

Depressed center grinding wheels (24 or 36 grit)

1. Aluminum oxide
2. Silicon carbide

 

How to Use Abrasives Safely

The first step in using any grinding product safely is choosing the right abrasive product for each machine. Check the manufacturer's catalog to see what products are designed for which machines. Some catalogs use icons to make the machine-to-abrasive match clear and easy.

Check the product packaging as well. It's tempting to ignore product packaging, but it provides a wealth of information, especially about safety. Read and follow the safety information on the product packaging, and mount it on your machine so your operators always have access to it.

 

Basic tips for using and maintaining abrasive products and machines safely include:

Safety Tips

• Don't grind near flammable materials.
• Grind and sand in well-ventilated areas whenever possible.
• Wear eye and face protection when working with any abrasive products.
• Wear a dust mask or approved respiratory protection. Check the packaging for the materials you're abrading or grinding to see which is recommended.
• Wear hearing protection. Pay attention to the noise exposure, and make sure you're protected when it exceeds established threshold levels.
• Wear safety gloves.
• Pay attention to where sparks are flying. Direct sparks away from your body and away from anyone else in the room.
• Don't wear loose-fitting clothing while grinding. Wear long-sleeved shirts or arm guards and long pants.
• If the tool you're working with starts to chatter or vibrate, stop at once. Find the cause of the problem, and fix it before you go any further.
• Use your abrasives on a first-in, first-out basis. Rotate your stock to keep the oldest abrasives ready at hand.
   

Grinding Wheel Tips

• Store your grinding wheels in a dry environment. Don't subject them to near-freezing temperatures or to dramatic temperature changes.
• If a wheel is cracked, chipped or otherwise damaged, don't mount it. If it has been dropped, don't mount it.
• Make sure that guards and work rests are all properly adjusted and secure before you start work. Safety guards should cover at least half of the wheel.
• Let a newly mounted wheel run for at least one full minute before grinding with it. Don't let anyone stand in front of or in line with the wheel during this time.
• Make sure flanges are clean, flat and free of burrs.
• Don't overtighten the flange retaining nuts.
• Compare the safe maximum operating speed of your grinding wheel with that of your grinder. Don't use a grinding wheel whose top-rated speed is less than the grinder's speed. Never exceed a grinding wheel's maximum operating speed.
• Never use a high-speed air sander with a grinding wheel. The speed of these pistol-grip air sanders far exceeds the maximum operating speed for grinding wheels. The result can be a potentially lethal wheel breakage. Many tragic injuries have resulted from using these high-speed sanders with grinding wheels. Don't let the next one happen on your watch. Instead, if you're using a high-speed air sander, only use sanding discs designed for the sander.
   

Fiber Disc Tips

• Store abrasive discs at the correct temperature and humidity: 60 to 80° F (15 to 29°C), and 40 to 50% relative humidity.
• Store coated abrasive discs properly. Keep them at least 4 inches (10+ cm) above the surface of concrete floors. Keep them away from open windows or heat sources and out of direct sunlight. Store them in their original packaging.
• If you receive an abrasive disc with damaged packaging, return it to the manufacturer. Don't use the disc.
• Check coated abrasive discs for damage before use. If you see any nicks, cuts, tears or other visible damage, don't use it.
• Never use a disc that has curled &#;sand side in&#; due to excess humidity.  Edges of the disc not in full contact with the backup pad create a hazard when grinding. 
• Never alter the size or shape of an abrasive disc or its back-up pad.
• Start up the tool just off the workpiece, and bring it up to full operating speed before you actually begin to grind or sand.
• As you start to grind or sand, ease the fiber disc onto the workpiece at a 5- to 10-degree angle to the piece's surface.
• If you're using a see-through disc or one with scooped holes, make sure nothing's protruding through any of the holes before you start up your equipment.
   

We all want higher productivity and lower cost, but safety comes first. Start by making sure your operators use their grinding and sanding equipment as if their lives depend on their safety precautions. Then use the correct abrasive products to get the job done right.

Contact us to discuss your requirements of abrasive industrial supplies. Our experienced sales team can help you identify the options that best suit your needs.