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Grind It Out

Grinding represents a major part of shop costs. Take a look at the latest generation of flap discs, wheels, brushes and other tools that can help save time, reduce costs and improve the efficiency of your metal finishing operations.

Posted: February 27, 2015

The XCAVATOR ultra high removal grinding wheel from Walter Surface Technologies is ideal for the toughest, most demanding grinding jobs in metal fabrication, steel mills, mining, oil and gas, and shipbuilding.

The XCAVATOR ultra high removal grinding wheel from Walter Surface Technologies removes over 30 percent more grams per minute compared to other ultra high removal wheels, while at the same time absorbing vibrations. This durable wheel can cost-effectively outlast all other grinding wheels in this category. Free of materials such as iron, sulfur and chlorine, it is virtually guaranteed not to contaminate surfaces such as stainless steel.

Enduro-Flex flap discs from Walter Surface Technologies are an ideal solution for finishing steel and stainless steel, removing 130 per cent more steel than leading competitors. They require fewer changeovers and ensure greater operational efficiency. (first view)

The VARILEX WSF 1800 speed-controlled surface finishing and blending tool from CS Unitec uses variable-speed control to double the service life of the abrasive disc while performing a multitude of tasks, from rough grinding and blending to polishing up to a mirror finish.

The VARILEX Surface Finishing Tool from CS Unitec is equipped with a patented EASY-LOCK clamping nut and spindle lock button that allows disc changes in seconds without tools, and an ergonomic, vibration-reducing, balanced handle for fatigue-free grinding.

The new bond from CGW-Camel Grinding Wheels provides greater form holding wheels, cooler grinding action and higher wheel dimension stability for more flexible grinding, eliminating the need for various grain types and wheels in the manufacturing process.

The new 212-page metal fabrication products catalog from CGW-Camel Grinding Wheels features Pasco sanding discs, premium resin fiber discs, an expanded cloth-backed belt program and a broadened coated abrasives section with specialty coated abrasives, such as 9 x 11 sanding sheets, cartridge rolls and spiral bands.

New PREDATOR AP Flap Discs from ARC Abrasives wear at a slower rate with increased cut over a normal flap disc, and are ideal for mild and stainless steel, as well as aluminum and other soft metals.

The taller inner cup of the high-speed, knotted-wire cup brush from Osborn forces the brush to be used on the tips of the knotted filaments, preventing bending and providing improved performance in the heavy-duty cleaning of metal surfaces.

The new 114-knot cutback brush from Osborn is perfect for angled removal of three or more layers of coating from pipe ends. It cleans the pipe edge, removes the pipe coating and grinds the coating angle, all at one time.

The 88-page four-color Load Runners® idler roller catalog offers specifications, diagrams, technical and application information, installation notes and quotation forms on a full line of cam followers, idler rollers and rail products in both metric and imperial, stud- or yoke-style, ranging in outside diameter sizes up to 12 in inside plain, flanged and V-groove design.

Type 27 Max Flex Cotton Fiber Wheels from Rex-Cut Abrasives are flexible for blending and finishing flat and contoured surfaces in one step without a back up pad. They can be used at a 45 deg angle for increased cutting and a 30 deg angle for smoother finishing.

Type 27 Cotton Fiber Grinding Wheels from Rex-Cut Abrasives provide smooth controlled grinding action, run cool, are non-loading on aluminum and eliminate the need for waxes and lubricants.

Tiger and Vortec flap wheels from Weiler Corporation are ideal for a variety of applications, from cleaning, edge blending, deburring and mismatch removal on machined parts, to smoothing metal, to the final finishes on metal surfaces and finish prior to painting and plating. These flap wheels yield great results when used for blending and finishing dies, molds, tools, tubing and channels.

The Abrasive Flap Disc Selection Guide from Weiler Corporation explains Premium Performance, High Performance and Fast Cut flap discs, has a user friendly reference for Grinding and Finishing Solutions, and lists selection criteria for choosing the right abrasive flap disc type, backing type and grain type to meet each specific application need.

ULTRA HIGH REMOVAL GRINDING WHEEL
Walter Surface Technologies (WST; Windsor, CT), a leader in innovative solutions for the metalworking industry, offers the XCAVATOR ultra high removal grinding wheel, the most powerful member of their innovative family of high performance grinding wheels to date. Designed for the toughest, most demanding grinding jobs for a range of industry metal fabrication shops such as metal fabrication, steel mills, mining, oil and gas, and shipbuilding, the XCAVATOR ultra high removal grinding wheel delivers heavy-duty performance and the highest level removal rate in the Walter range of industry-leading grinding wheel products.

Tested on some of the world’s hardest resources – including tungsten carbide, tempered steel, Inconel, Hardox, and Boron steel – this grinding wheel’s extra aggressive, coarse front layer of enriched Zirconium grain has gone through rigorous testing to help deliver the industry’s highest removal rates. A powerful wheel for powerful industry environments, XCAVATOR helps ensure optimal power transfer – from operator to working surface – for the toughest jobs. It features an extra strong disc base/backing for more powerful and aggressive grinding action. It also features Walter patented UHR multi-layer manufacturing technology to prevent edge flakiness – keeping the wheel edge symmetrically round for more safety and longer life.

Grinding represents a major part of shop costs and XCAVATOR stands tall as a heavy-duty grinding wheel that helps save time, save money and is built to last. Created for use with powerful grinding machines, XCAVATOR performs removes over 30 percent more grams per minute compared to other ultra high removal wheels, while at the same time absorbing vibrations, allowing this durable wheel to cost-effectively outlast all other grinding wheels in this category. Free of materials such as iron, sulfur and chlorine, this grinding wheel is virtually guaranteed not to contaminate surfaces such as stainless steel.

The company also offers the most durable flap discs on the market that are now better than ever before in the cutting edge Enduro-Flex and Enduro-Flex Turbo flap discs for metal finishing applications – each earning high marks in finishing performance, removal rate and cost efficiency.

Enduro-Flex is designed as the ideal solution for finishing steel and stainless steel, Enduro-Flex flap discs require fewer changeovers, which help reduce waste and ensure greater operational efficiency. In comparative tests between flap discs, Enduro-Flex set the industry standard with 130 per cent more steel removed than leading competition. This saves both time and costs while simultaneously providing an environmentally sound solution. A 5 in disc with 40 grit removes up to 2,500 grams over its lifespan

Enduro-Flex is also an eco-friendly alternative. When it comes to metal fabrication and finishing, having high performance and being eco-friendly are no longer mutually exclusive. In addition to being the highest performing finishing discs on the market, Enduro-Flex foregoes traditional plastic backing with an innovative Eco-Trim backing made from a base of natural and sustainable plant fibers. Using less plastic reflects a clear commitment to reducing the overall ecological footprint. A percentage of Enduro-Flex sales goes to funding the planting of new trees to regenerate forests for future generations.

Enduro-Flex Turbo is an industry leader in ultra high speed removal times, with 60 percent more material removal than before. It is the fastest cutting flap disc in the industry today. Designed for weld removal, edge breaking and blending applications, the Enduro-Flex Turbo is faster than ever – delivering top performance via a unique proprietary mixture of high content self-sharpening grains. It uses built-in Cyclone Technology along with an innovative flap configuration that enables operators to perform with an ultra-fast cutting rate of a 36 grit with the finish of a 60 grit. Enduro-Flex Turbo also provides patented Turbofan cooling technology, meaning the piece being worked on stays cooler by at least 10 percent. This translates into less surface damage and longer disc life. Whoever can grind or clean the most, the quickest, and the finest, wins hands down — the enhanced Enduro-Flex Turbo works fast on both steel and stainless.

Walter Surface Technologies has grown as a leader in surface treatment technologies for more than 60 years, providing high productivity abrasives, power tools, tooling, chemical tools and environmental solutions for the metal working industry. Founded in Montreal in 1952, the company is now established in seven countries throughout North America, South America and Europe. International headquarters are located in Montreal and U.S. headquarters are located in Windsor.

Walter Surface Technologies, 810 Day Hill Road, Windsor, CT 06095, 860-298-1100, www.walter.com.

POWERFUL MULTIFUNCTIONAL SURFACE FINISHING TOOL
The new and improved VARILEX® WSF 1800 speed-controlled surface finishing and blending tool from CS Unitec, Inc. (Norwalk, CT) provides 25 percent more power and increased productivity. With a powerful 15.9 amp (1,710 watt) motor and infinite variable-speed control (2,000 rpm to 7,600 rpm), the operator can perform a multitude of tasks from rough grinding and blending to polishing up to a mirror finish. VARILEX comes standard with a 5 in safety guard.

Variable speed control has important benefits. It doubles the service life of the abrasive disc. It prevents glazing of the disc and heat deformation of the work piece. It also drastically reduces the noise level. Another unique feature of the VARILEX motor is its tacho-generator feedback technology that keeps the power output and torque constant while operating at any rpm. The result is a uniform finish. The sensitive variable-speed control makes this ideal for use with flap discs, grinding and polishing discs, as well as the FIX Hook and Loop polishing system, cleaning discs and cutting wheels, for applications ranging from grinding to blending, pre-polishing and polishing. The variable-speed control:

Doubles the service life of the disc being used.
Prevents glazing of the disc and heat deformation on the workpiece.
Drastically reduces the noise level.

Designed and developed for heavy industrial use, the VARILEX Surface Finishing Tool is equipped with a patented EASY-LOCK clamping nut and spindle lock button allowing the user to change discs in seconds, without tools. The spindle thread connection is a standard 5/8-11 UNC. An ergonomic, vibration-reducing, balanced handle allows fatigue-free grinding and the quick lock style power cord allows for easy tool change and a safer working environment. Safety guards from 4-1/2 in to 7 in are available for use with various-size grinding, blending and polishing discs of 4 in to 7 in diameter. The VARILEX differs from a conventional angle grinder in its motor design to allow for exceptional performance at low rpm – without motor overheating or burnout. It also offers:

Optimal speed setting for a range of grinding and polishing tools, yielding perfect results every time.
A balanced handle that ensures fatigue-free grinding.

Works with the Flexible Drive Shaft.

CS Unitec, Inc., 22 Harbor Avenue, Norwalk, CT 06850 203-853-9522, info@csunitec.com, www.csunitec.com.

ADVANCED BOND IMPROVES SURFACE, CYLINDRICAL, CENTERLESS GRINDING
CGW-Camel Grinding Wheels, USA (Niles, IL) has introduced an improved bond used in manufacturing vitrified wheels for the surface grinding, cylindrical and centerless wheel categories. The next-generation bond provides greater form holding wheels, cooler grinding action and higher wheel dimension stability. Vitrified wheels made with the new bond are more flexible during grinding, eliminating the need for various grain types and wheels in the manufacturing process. One vitrified wheel made with the new bond can accomplish the same results as multiple wheels. The new bond also lengthens life spans, improving cost efficiency and enhancing workpiece quality.

The company has also released a new metal fabrication and industrial products catalog that features Pasco sanding discs, premium resin fiber discs and an expanded cloth-backed belt program. The new catalog features a broadened coated abrasives section including specialty coated abrasives, such as 9 x 11 sanding sheets, cartridge rolls and spiral bands. The 212-page catalog is CGW’s largest catalog to date and features color-coded product sections and QR codes linked to feature product videos. “This new products catalog showcases our CGW/Pasco product line for the metal fabrication and industrial markets. We now offer more than 6,000 abrasives products ,” explained Joe O’Mera, the president of CGW-Camel Grinding Wheels. To view the catalog online, visit cgwcamel.com.

CGW-Camel Grinding Wheels is a leading manufacturer and supplier of grinding wheels since 1956. CGW has more than 185,000 sq ft of manufacturing and distribution space in Niles and Buena Park, CA.

CGW-Camel Grinding Wheels, 7525 North Oak Park Ave, Niles, IL 60714, 800-447-4248, Fax: 800-447-3731 sales@cgwcamel.com, cgwcamel.com.

FLAP DISCS WEAR SLOWER WITH INCREASED CUT
ARC Abrasives, Inc. (Troy, OH) offers their new PREDATOR™ AP Flap Disc line, part of the new PREDATOR Advanced Products (AP) group that shows an advancement in performance over the current product offering. These AP flap discs have an industry-best cut and life, with flaps that lay flatter than the flaps on a conventional flap disc to allow the AP flap disc to wear at a slower rate with increased cut over a normal flap disc. AP flap discs utilize cutting-edge technology that gives them a new look and feel and offers excellent performance on mild and stainless steel. The addition of Performance Coating offers the same great performance for use on aluminum and other soft metals. Get your FREE sample today! Call customer service at 800-88804885 for more information and reference code “FD14TJ” for your free sample.

http://youtu.be/bKPBFiJLQ9A

ARC Abrasives, Inc., 85 Marybill Drive, Troy, OH 45373, 937-335-5607, www.arcabrasives.com.