Non Woven Abrasives Unraveling the Mystery Production Process - PowerPoint PPT Presentation

Non Woven Abrasives Unraveling the Mystery

Production Process Plant Tour in Pictures

Spray Impregnation Fiber Blender Spray Impregnation Rolling Needling Carding Fiber

Fiber

Physical Properties • Type – Polyester vs Nylon • Cost vs performance • Denier – Size matters • Strength • Flexibility • Durability • Cut Color Dyed vs natural

Resin

Phenol vs Urethane • Phenol attacks fiber • Phenol is temp resistant • Urethane is more flexible • Urethane is more expensive • Phenol changes color • Urethane has better adhesion to Nylon

Principle of Function

Position of Non Woven products in relation to other abrasive media Heavy Light Stock Conditioning Scratch Stock removal / Surface / removal / removal good finish Good finish polishing Bonded Abrasives Coated Abrasives Wire / Filament Products Non Woven Products Polishing Buffs / Wheels Grit / Set up wheels

Coated vs Nonwoven nonwoven abrasive coated abrasive • Scratch depth • Micro deburring • Consistency of finish • Lower temperature

Comparison of abrasive cut over time for a P120 grit coated abrasive compared to a Coarse A surface conditioning disc 40 35 30 P120# CRS A 25 Cut / g 20 15 10 5 0 5 10 15 20 25 30 Time / mins

Comparison of abrasive finish over time for a P120 grit coated abrasive compared to a Coarse A surface conditioning disc 2.4 2.2 2 ____ P120 coated 1.8 ____ CRS A scm 1.6 1.4 1.2 1 0.8 0.6 0.4 1 5 10 15 20 25 30 Time (Minutes)

Surface finish comparison Profile=R_ISO - Section=[1] • P60 Resin Fiber Disk [um] 5.159 3.333um/cm, x3000.000 • Ra = 2.24 -1.507 • Rt = 13.17 -8.174 • Rz = 11.94 0.400 2.400 [mm] 4.400 Profile=R_ISO - Section=[1] 0.291mm/cm, x34.375 • P120 Resin Fiber [um] 6.270 3.333um/cm, x3000.000 Disk -0.396 • Ra = 0.5 -7.063 • Rt = 3.17 0.400 2.400 [mm] 4.400 • Rz = 2.97 Profile=R_ISO - Section=[1] 0.291mm/cm, x34.375 [um] 6.310 • Coarse SCM (P60) 3.333um/cm, x3000.000 • Ra = 0.45 -0.357 • Rt = 3.5 -7.024 • Rz = 2.9 0.400 2.400 [mm] 4.400 0.291mm/cm, x34.375

Surface finish comparison Profile=R_ISO - Section=[1] [um] 1.604 • P120 Resin Fiber Disk -0.396 • Ra = 0.5 • Rt = 3.17 • Rz = 2.97 -2.396 [um] 1.955 • Coarse SCM • Ra = 0.45 • Rt = 3.5 -0.357 • Rz = 2.9 -2.670

Temperature increase over time for a P120 grit coated abrasive compared to a Coarse A surface conditioning disc 300 250 200 Temp / deg C 150 100 120# S / Steel SCM S / Steel 50 120# Aluminum SCM Aluminum 0 0 5 10 15 20 25 30 35 40 45 50 55 60 time / secs

Foam Vs. Nonwoven Foam shares properties of both Coated and Non-Wovens – Flexibility – Conformability – 2 dimensional abrasive structure – Surface finish changes over time – Shaped forms (built in tool)

Application

Fleece • CF – Nylon, smaller denier, phenolic. – Handwork, handpads etc. – Light machine finishing • HD – Nylon, large denier, more resin and grit. – Heavy Machine Finishing – Intricate Shapes • SD – Nylon, urethane – Deburring / Edge breaking – Flexibility to access extreme angles

Surface Conditioning Material • Applications for Belts – Cookware – Hardware – Metal Fabrication • Applications for Disks – Weld blending – Refining Coated abrasive grind lines

Technical Wheels • Unitized – Deburring – Weld Blending – Cleaning • Convolute – Deburring – Finishing