Abrasive Products for Grinding and Finishing of Hard Coatings

3 Abrasive Products for Grinding and Finishing of Hard Coatings Application Guide

Life after chrome: It s not the same old grind. Increasing restrictions on the use of hexavalent chrome have hastened the switch to thermal spray hard coats and other advanced materials in high performance corrosion control and wear-resistance applications. Traditional grinding and finishing methods are proving less effective on many of these newer, hard-to-grind materials slowing down production and driving up costs. Now, 3M brings you a broad range of solutions designed to meet today s tough processing challenges. From grinding-todimension all the way to superfinishing, 3M has the tools you need to achieve stringent geometry tolerances and finish specs, part after part. Compared to traditional bonded wheels and honing stones, 3M abrasive belts are easier to use, and less dependent on operator skill for more consistent, predictable results. And because they cut faster, and don t require dressing, 3M abrasive belts can help you increase production without the need to invest in new machines or add shifts. The 3M Customer Abrasive Methods (CAM) Center, located at 3M s St. Paul, Minnesota, headquarters, was established to help customers identify the most cost-effective combination of abrasives, equipment and techniques for their particular applications. At the CAM Center, evaluations are carried out under controlled, repeatable conditions using a wide array of production scale grinding, polishing and finishing equipment, as well as in our on-site research and testing laboratories. Just as important, 3M offers you the technical support and application development resources backed by over 100 years of abrasives experience to help optimize your process, and take full advantage of all the benefits these exciting new technologies have to offer. The services of the 3M CAM Center include applications development, process optimization, operator training and other technical support. Contact your local 3M representative for more information.

3M Abrasive Technologies 3M Trizact Abrasives Derived from patented 3M microreplication technology, Trizact abrasives consist of preciselyshaped three-dimensional structures distributed uniformly over the substrate. Unlike conventional abrasives, which are constructed from randomlyspaced and irregular-shaped minerals, the uniform configuration of Trizact abrasives helps deliver more consistent performance and eliminate belt-tobelt variation. Trizact belts start sharp and stay sharp, resulting in more predictable finishes and improved, consistent quality in your parts. Lower costs Trizact belts can last two to five times longer than conventional belts and finish so precisely that operators can reduce grade sequences, which in turn can reduce total cost of operations. Conventional abrasives start out sharp, but dull quickly The three-dimensional structures of 3M Trizact Abrasives contain multiple layers of mineral. As these structures wear, fresh, sharp mineral is constantly exposed to the workpiece, resulting in faster, more consistent cutting throughout the life of the belt. 3M Cubitron Abrasive Grain Today s abrasives Coating Removal Courtesy of Abbott Machine Co. 3M Trizact Diamond Cloth Belt 663FC 3M Cloth Belt 966F 3M Trizact Diamond Cloth Belt 663FC represents the next generation in abrasive technology combining the predictable dimensioning traditionally associated with bonded wheels with the speed, consistency and ease of use of 3M abrasive belts. Designed for grinding hard materials to final dimension, 663FC belts also work well for stripping old thermal spray coating during the refurbishment process. 663FC belts cut up to 70% faster than bonded wheels without chatter. And because they are easy to use, even lessexperienced operators can achieve consistent, effective stock removal throughout the life of the belt. Constructed with tough, durable Cubitron abrasive grain, 966F belts are ideally suited for stripping chrome from old parts as they are being rebuilt. 966F belts are also suited for wet grinding and finishing of heat sensitive high nickel alloys, where a coolant flood is needed, as well as titanium and stainless steel. Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Ideal for moderate to heavy stock removal 3M-patented Cubitron Abrasive Grain is one of the hardest, longest-lasting minerals available. It is engineered to cut fast and stand up to the intense heat and stress generated in heavy grinding applications. It is an ideal mineral for grinding stainless steel, titanium and heat sensitive nickel alloys. 3M Flexible Diamond Belts 3M Flexible Diamond Belts help you achieve better finishes without sacrificing cut rates on hardto-grind roll materials. A metal bond securely anchors microngraded diamonds to a premium, flexible backing. This provides durability and long life, while allowing conformance to a variety of contours. The open dot pattern produces aggressive cutting action and reduces grinding loads. T H E R M A L S P R

for processing today s new materials Base Material Prep & Dimensioning 3M Diamond Cloth Disc 673W 3M Diamond Cloth Discs 673W are designed to provide long-lasting cutting performance when used for finishing and dimensioning ceramics, carbides and hardcoated materials. They are an excellent choice for removing coating overspray or removing coatings prior to refurbishment. The unique construction allows Diamond Cloth 673W to deliver outstanding consistency throughout the life of the disc, for improved control and fewer rejects. They provide optimal performance when run wet, but can also be run dry. Compared to flexible metal bond diamond abrasives, 3M Diamond Cloth Discs 673W last longer, and deliver a faster, more consistent cut. They also provide a finer finish, with less chance of burn through helping you improve productivity. 3M Trizact Cloth Belt 953FA 953FA belts have proven to be an ideal choice for wet centerless grinding and finishing operations. The product also provides outstanding performance at dimensioning the base material of thermal spray parts prior to coating. 953FA belts combine the unmatched consistency of Trizact abrasive products with the durable performance of 3M Cubitron Abrasive Grain. This patented new shape, packed with durable Cubitron grain, introduces a full line of consistent Trizact belt products now for stock removal through final finishing in wet applications. The macroreplicated abrasive structure of 953FA belts results in very predictable, consistent cut and finish performance on stainless, mild and hardened steel. Grade range: A300 to A6, in belts up to 25" wide. Faster than conventional bonded wheels A 20% higher belt cut rate than competitive 3D belt products Up to 5 times extended belt life over conventional coated abrasives Improved finish consistency Reduced taper on long parts Improved part-to-part size 3M Trizact Cloth Belt 963FA Similar to 953FA belts above, new 963FA belts offer a new stronger polyester backing with patented adhesion enhancers, increasing their durability in applications such as coarse Grades A100-A6 Grades A500-A160 grade stock removal. In medium and fine grades, 963FA belts deliver improved finishes and improved final part size consistency. Available in grades A500 to A6 in belts up to 25" wide. A Y C O A T I N G S C E R A M I C S

Grinding Cylindrical Courtesy of Abbott Machine Co. 3M Trizact Diamond Cloth Belt 663FC 3M Trizact Diamond Cloth Belt 663FC represents the next generation in abrasive technology combining the predictable dimensioning traditionally associated with bonded wheels with the speed, consistency and ease of use of 3M abrasive belts. 663FC belts cut up to 70% faster than bonded wheels. And because they are easy to use, even less-experienced operators can achieve consistent, effective stock removal throughout the life of the belt. This also means that lower grinding forces can be used, avoiding deformation, chatter and other grinding defects on lightweight/thinwalled components. Contour/Complex Shape 3M Diamond Cloth Disc 673W 3M Diamond Cloth Discs 673W are designed to provide long-lasting cutting performance when used for finishing and dimensioning ceramics, carbides and hardcoated materials. The unique construction allows Diamond Cloth 673W to deliver outstanding consistency throughout the life of the disc, for improved control and fewer rejects. They provide optimal performance when run wet, but can also be run dry. Compared to flexible metal bond diamond abrasives, 3M Diamond Cloth Discs 673W last longer, and deliver a faster, more consistent cut. They also provide a finer finish, with less chance of burn through helping you improve productivity. 3M Flexible Diamond Belts 3M Flexible Diamond Belts provide an alternative to bonded wheels that can help you achieve required finishes without sacrificing cut rates on hard-togrind roll materials. A metal bond securely anchors micron-graded diamonds to a premium, flexible backing. This provides durability and long life, while allowing conformance to a variety of contours. The open dot pattern produces aggressive cutting action and reduces grinding loads. 3M Resin Bond Superabrasive Wheels 3M manufactures a full line of bonded and single layer superabrasive products utilizing the latest induction and furnace heating techniques. They provide excellent form retention as well as abrasion and heat resistance when grinding tough materials such as carbides, quartz, ceramics, and hard metals. C A R B I D E S H A R D C O M P O

Superfinishing/Finishing 3M Diamond Microfinishing Film 675L Designed especially for fast finish reduction on hard materials, new 675L film allows target finishes to be achieved in fewer passes for greater productivity. Can cut superfinishing time in half or more, compared to stones. Currently available in grades ranging from 125 to 20 micron, 675L film offers an efficient, economical alternative in most applications except those requiring the finest possible finishes. Use 3M Diamond Lapping Film to achieve finishes <2 Ra. 3M Diamond Lapping Film 663X/661X 3M Diamond Lapping Films are widely used for finishing and polishing hard to grind materials such as carbide, ceramics, hardened metals, exotic alloys and composites. They combine micron-graded diamond particles, a resin bonding system and a highly uniform polyester film backing for a more consistent, cleaner and faster alternative to diamond compounds or slurries. The following products can be used as alternatives for achieving a final finish for customers without superfinishing equipment. 3M Diamond Polishing Cloth Belt 652WY Long-lasting and cost-effective. Micron graded diamond particles encapsulated in a ceramic bead and resin bonded to a durable cloth backing. Designed for use on materials harder than 7 on Mohs scale (800 Knoop). Compared to bonded wheels and conventional abrasives, 3M Diamond Polishing Cloth can reduce process time with fewer steps and excellent finish. The water-resistant backing performs well in both wet and dry applications. And the products overall toughness makes them ideal for many hard-to-finish materials, including thermal spray parts, ceramics, composites, HVOF coatings, chilled iron and non-ferrous metal. Available in 0.5, 3, and 6 and 9 micron grades. 3M Diamond Cloth Belt 651WY Micron graded diamond particles affixed to a durable cloth backing with a tough resin bond. Plain cloth backing. Available in 9-165 micron grades. 663X film features a stronger resin system that provides added toughness and longer product life. Available in 15, 30, 45 and 60 micron grades. 661X film has a 3 mil polyester backing, and is available in 0.1-30 micron grades. 3M Flexible Diamond Rolls & Belts Used in rolls on superfinishers or in belt form, Flexible Diamond products allow you to achieve your required finish. In some cases, Flexible Diamond products can be used to roughen up parts when a frictional surface is needed. S I T E S C H I L L E D I R O N

Process Recommendations and Expected Results 3M s technical service engineers recommend the following sequences for grinding and finishing of hard coatings. Your actual process and finishes may vary depending on your equipment, parts and material. Chrome Stripping with 3M Cloth Belt 966F Operating Conditions Contact Wheel Alternate Contact Wheel Abrasive Speed Rod Rotation Head Traverse Speed Head Motor Load Incompressable Aluminum, Steel, Polymer; 90 Shore A, smooth or serrated 6000 7000 sfpm 100 sfpm.020.070 /revolution (depending on chrome/coating thickness) 33% over no-load Coating Removal with Diamond Cloth Belt 663FC Belt Speed (SFPM) 6,000 4,000-7,000 Speed 75 50-150 Traverse Rate 1/8 inch/rev 1/10-1/4 inch/rev Contact Wheel Incompressable Aluminum, Steel, Polymer; Alternate Contact Wheel 90 Shore A, smooth or serrated Base Material Prep & Dimensioning with 3M Cloth Belt 966F Base Material Prep & Dimensioning with 3M Trizact Cloth Belt 953FA Mild Steel Hardened Steel Roll Grinding with 3M Trizact Diamond Cloth 663FC Roll Material Thermal Spray Coatings: Grade Stock Removal (Inches) Finish (Ra Micro-Inch) 24 0.010 0.015 >200 36 0.007 0.010 160 190 40 0.005 0.009 140 180 50 0.005 0.008 130 170 60 0.004 0.007 120 150 80 0.003 0.006 100 130 Contact Wheel Incompressable Aluminum, Steel, Polymer; Alternate Contact Wheel 90 Shore A, smooth or serrated Belt Speed (SFPM) 6,000 4,000-7,000 Speed 75 sfpm 50-150 Traverse Rate 1/8 inch/rev 1/10-1/4 inch/rev Sequential Surface Finishes Obtained Ra (micro inch) Infeed (inches on radius) 70µ 40µ 20µ Tungsten Carbide Ra 20-30 10-20 4-10 Infeed 0.0008 0.0005 0.00025 Chrome Carbide Ra 25-35 15-25 6-12 Infeed 0.0012 0.0008 0.0005 Nickel Based Ra 40-50 30-40 20-30 Infeed 0.0017 0.0012 0.0006 Chrome Oxide Ra 60-80 40-50 20-30 Infeed 0.003 Belt Speed (SFPM) 6,000 4,000-7,000 Speed 75 50-150 Traverse Rate 1/8 inch/rev 1/10-1/4 inch/rev Contact Wheel Incompressable Aluminum, Steel, Polymer; Alternate Contact Wheel 90 Shore A, smooth or serrated Mild Steel Hardened Steel Grade Stock Removal (Inches) Finish (Ra Micro-Inch) A300 0.002-0.003 68/470 A160 0.001-0.0015 61-428 A100 0.001 45/312 A80 0.0008 38/290 A65 <0.001 33/245 A45 <0.001 21/154 A30 <0.001 14/114 A16 <0.001 10/75 A10 neg. 5/41 A6 neg 3/25 Belt Speed (SFPM) 6,000 4,000-7,000 Speed 75 50-150 Traverse Rate 1/8 inch/rev 1/10-1/4 inch/rev Contact Wheel Incompressable Aluminum, Steel, Polymer; Alternate Contact Wheel 90 Shore A, smooth or serrated Superfinishing with 3M Diamond MicrofInishing Film 675L Roll Material Thermal Spray Coatings: Sequential Surface Finishes Obtained (Ra Micro inch) 74µ 45µ 30µ 20µ Tungsten Carbide Ra 12-16 8-12 5-8 2.5-5 Chrome Carbide Ra 15-20 10-14 6-10 4-6 Nickel Based Ra 20-55 14-19 6-10 4-6 Chrome Oxide Ra ~55 ~45 Speed 300 sfpm 150-350 Traverse Rate 0.07 inch/rev 0.03-0.1 Abrasive Support 65 Shore A Roller Abrasive Speed 1 inch/min Pressure 20 lbs/inch width 10-40 Oscillation Alternating Moderate/None Superfinishing with 3M Diamond Lapping Film Roll Material Thermal Spray Coatings: Tungsten Carbide Chrome Oxide Aluminum Oxide Ra Sequential Surface Finishes Obtained (Ra Micro inch) 30µ 15µ 9µ 3µ 2 (2 passes required) 1 2 1 <1 Rmax 49 39 25 15 Speed 300 sfpm 150-350 Traverse Rate 0.07 inch/rev 0.03-0.1 Abrasive Support 65 Shore A Roller Abrasive Speed 1 inch/min Pressure 20 lbs/inch width 10-40 Oscillation Alternating Moderate/None

Convert your wheel grinder into a high performance machine capable of using 3M Superabrasive products and increase your capacity up to 3X! It s like adding two new grinders with a minimal investment in new equipment. 3M has partnered with equipment builders who will work with you to convert your existing grinder into a flexible tool, capable of utilizing both wheels and 3M superabrasive belts. Bonded wheel conversion by Abbott Machine Company Alton, Illinois Now you can experience increased production, ease of use and consistent performance of 3M abrasive belt technology on your existing bonded wheel grinder for as little as 5% of the cost of a new machine! By reducing the cost of each part produced, your converted grinder can pay for itself in as little as six months. Contact your 3M representative for more details Bonded wheel conversion, superfinisher combination by Finishers Tech Product Use: All statements, technical information and recommendations contained in this document are based on tests or experience that 3M believes are reliable. However, many factors beyond 3M s control can affect the use and performance of a 3M product in a particular application, including conditions under which the product is used and the time and environmental conditions in which the product is expected to perform. Since these factors are uniquely within the user s knowledge and control, it is essential that the user evaluate the 3M product to determine whether it is fit for a particular purpose and suitable for the user s method of application. Warranty and Limited Remedy: Unless stated otherwise in 3M s product literature, packaging inserts or product packaging for individual products, 3M warrants that each 3M product meets the applicable specifications at the time 3M ships the product. Individual products may have additional or different warranties as stated on product literature, package inserts or product packages. 3M MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR ANY IMPLIED WARRANTY ARISING OUT OF A COURSE OF DEALING, CUSTOM OR USAGE OF TRADE. User is responsible for determining whether the 3M product is fit for a particular purpose and suitable for user s application. If the 3M product is defective within the warranty period, your exclusive remedy and 3M s and seller s sole obligation will be, at 3M s option, to replace the product or refund the purchase price. Limitation Of Liability: Except where prohibited by law, 3M and seller will not be liable for any loss or damage arising from the 3M product, whether direct, indirect, special, incidental, or consequential regardless of the legal theory asserted, including warranty, contract, negligence or strict liability. 3 Industrial Business Bldg. 21-1W-10 900 Bush Av. St. Paul MN 55144 1-866-279-1235 www.3m.com/industrial 3M, Cubitron and Trizact are trademarks of 3M Company. Used under license by 3M subsidiaries and affiliates. Issued: 5/06 2006 3M 5284 (HB) 61-5002-8137-5