How to choose suitable surface treatment products?
Choosing the right product for grinding and surface treatment applications can be annoying, because many types of abrasive products can be used for work, and each product has many different sizes, textures, and styles.
For example, when you use a right-angle grinder, the choice of tools includes grinding wheels, folded plates and resin fiber discs, each of which has its own advantages and limitations.
Compare the three types in this article, assuming that each die type and wheel size you use are the same.
Grinding wheels usually provide the longest product life and maximum durability, but they also produce relatively slow cutting speeds and the roughest surfaces. Regarding the price, the grinding wheel is in the middle of these three options.
The flap disc can provide fast cutting and sufficient life. The service life is longer than that of the resin fiber disc, but not as long as the grinding wheel. The main advantage of flap discs is that they can be ground and finished at the same time. Moreover, they grind and polish at a constant speed during the life of the disc. Auctions usually have the highest initial purchase price of the three products.
The resin fiber disc has the worst durability and the shortest lifespan, but the initial purchase price is also the cheapest. The resin fiber disc can be cut quickly in a short time. However, the particles will wear out and become blunt when used for the first time, which means that the cutting speed and surface finish will continue to decrease when the disc is used.
In addition, the resin fiber disc must be paired with a support pad to support it, which increases the cost. Choosing the right backing plate will affect the rigidity and performance of the disc. If you use a resin fiber disc with a flat mandrel hole, the lock nut that fastens the disc to the liner may cause interference when grinding at a small approach angle or in a narrow area.
After understanding the differences and advantages of these three products, you should answer the following questions before choosing.
Question 1: Is the surface finish important?
If the answer to this question is no, then the grinding wheel is a completely acceptable choice. Because it has a longer life and durability, it saves costs than using flap disks, and the initial purchase price is lower.
If the answer is yes, it is best to use a flip-top disc, because you can use it for mixing and maintain a consistent finish in one use without the need for a separate product for grinding and finishing.
The resin fiber disc will be ground and finished, but remember that as the use time increases, its finish and cutting speed will decrease.
Finally, you can use a grinding wheel to complete this process, but because the grinding wheel will leave a rough surface, you need to use auxiliary tools for finishing. Although using two tools instead of one tool can help extend the product life of finishing tools, it also increases the labor time required to complete the work.
Question 2: Does price matter?
If you are initially concerned about the initial purchase price of the product, the resin fiber disc is the cheapest option. Remember, these discs are best for small jobs. Initially their cutting speed is fast, but compared to flaps or grinding wheels, they wear quickly.
Although the initial purchase price of resin fiber discs is relatively low, you may need to buy 15 or 20 discs to get the same service life as a clamshell disc. Please keep in mind that the use of resin fiber discs also requires the purchase of a backing plate.
Buying a flap disk at a higher initial price can provide a greater return on investment. When looking at the purchase cost, be sure to consider how many grinding and finishing operations are required to ensure the best value.
Question 3: Do I need higher productivity?
If you want to increase productivity or productivity or reduce labor costs, choosing finishing tools will affect time and cost savings.
If you need fine surface treatment, the flip-top disc can be ground and finished in one go, so it can bring the greatest benefit to overall productivity, thereby saving you time.
In the case where the surface finish is not important, due to the overall cutting rate of the product, longer life expectancy and durability, the use of grinding wheels can help increase productivity and productivity. More work can be done, and tasks can be completed.
Question 4: Am I worried about damaging the workpiece?
Grinding wheels generally have a greater chance of damaging the workpiece, especially if you push hard or the wheels slip, because they are harder than folded plates or resin fiber discs. When making the first stroke, especially when using a new grinding wheel, please pull the grinding wheel toward you instead of pushing it away to reduce the chance of gouging. The reflow of gouging leads to an increase in the cost of material damage, or a waste of time to eliminate the error.
In addition, grinding wheels have a greater tendency to retain heat than baffles or resin fiber sheets. For example, when using a grinding wheel on stainless steel, due to excessive heat, this heat can cause the material to "turn blue" (the surface actually turns blue). This in turn leads to increased costs of damaged materials or increased rework time.
Flap discs are generally more forgiving, so if you push hard or slip, there is less chance of gouging the material. Resin fiber discs can also be more tolerant, depending on the hardness of the liner used.
For best results, please consider your options
Although you have many product choices for grinding and surface finishing, it is important to understand the advantages and disadvantages of each product to get the best results and complete your job needs. Maybe product life is the most important factor, or you are looking for the fastest entry point. Is the initial purchase price a key consideration, or are you more interested in increasing productivity and output?
Although there is no one-size-fits-all solution, knowing your goals and objectives can help you narrow your choices and choose the most suitable product for your job.
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