Абразивные материалы для металлообрабатывающей промышленности

3M Абразивные материалы

Новые решения

Абразивные материалы для металлообрабатывающей промышленности



Cubitron™ Абразивные материалыдля зачистки



Trizact™ Структурированные абразивы для шлифовки и полировки



Scotch-Brite™ Материал для доводочных работ



Cubitron - Минерал помогающий достичь наилучших результатов

Trizact - Ничто не работает так долго как пирамиды

Scotch-Brite - Лучший выбор для доводки поверхности

Шлифовка - Выбор абразива и впечатляющие результаты

Доводка - Выбор абразива и впечатляющие результаты

Полировка - Выбор абразива и впечатляющие результаты

Большой ассортимент абразивных материалов - Правильное решение любых поставленных задач


Новые решения3MInnoQu.ppt

Нержавеющая сталь,

Никелевые сплавы,

Титан,

Cobalt-Chrome

TrizactTM(237AA, 307EA, 407EA)CubitronTM (977F, 907E, 3M 967F)Объемные круги Scotch-Brite EXLЛенты Scotch-Brite

Высокоточные деталиТурбинные лопатки, Хирургический инструмент,

Имплантанты



Декоративные ИзделияКраны, Ручки, Автомобильные детали,

Посуда, Драгоценности

Черные иЦветные Металлы

Trizact ™(237AA, 307EA, 407EA, 3M217EA, 3M 227AA)

Cubitron™ (907E)



ИнструментМолотки, Режущий инструмент, Гаечные ключи

Инструментальная сталь, Углеродистаясталь

CubitronTM ( 3M 961F Высокое давление

3M 963F Низкое давление)



Конструированное литье

Серый литейный чугун, Алюминий, Латунь, Медь

CubitronTM (963F)Scotch-Brite wheels



ТрубыПищевая, химическая, энергетическая промышленности,

Строительство, Архитектура

TrizactTM (253WA, 453WA, 366FA)CubitronTM (963F, 977F, 3M 967F)Алмазный инструмент

Нержавеющая сталь,Титан,Черные и цветныеметаллы



Минерал помогающий достичь наилучших результатов

Почему минерал Cubitron™ является лучшим абразивным зерном?

Прочный

Сконструирован так чтобы оставаться острым

Стабилен при нагреве



Кристаллы Cubitron имеют встроенные микроизломы, которые обеспечивают восстановление острых краев минерала во время использования

Обычные кристаллы в скором времени сглаживаются или катастрофически разрушаются



Минерал Cubitron™:

острее

прочнее

высокая износостойкость

высокая скорость обработки

значительно меньше нагрев обрабатываемого материала



1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 190%

20%

40%

60%

80%

100%

120%

Cubitron

AluminaZirconia Aluminium

Oxide

Total stock removal

Шлифовальные циклы

Проведенные испытания показали, что при обработке инструментальной стали, абразивыс минералом Cubitron продолжают работать, даже после того как остальные уже давно износились.

Уд

ален

ие

мат

ери

ала

за ц

икл



Правильное решение любых поставленных задач

Минерал

Cubitron™:Оксид Алюминия:Карбид кремния:

Основа

Полиэфирная ткань:(Все абразивы на полиэфирной основе могут использоваться с водой)Очень гибкая:Гибкая:Жесткая:Очень жесткая:

Покрытие

Открытоеt: Закрытое:

Добавки

Смазка:

Связка

Синтетическая смола:

Максимальная ширина (mm)

Цвет

Плотность

CUAOSC

XE, XF, YF, YN

JJEXYF

OP

CL

GA

R



Ленты Cubitron™ серии 9

К о д

3M 907E

3M 961F 3M 963F

3M 967F

3M 977F


CU

CU

CU

CU

CU

JF

YF Flex

YF

YF

YF

CL

CL

CL

CL

CL

GA

-

-

GA

GA

R

R

R

R

R

Минерал Основа Покрытие Добавка Связка



24 36 40 50 60 80 100 120 150 180 220 240

3M 907E

3M 961F

3M 963F

3M 967F

3M 977F



Зернистоть

Грубая шлифование Шлифование Полировка

Чем мельче зерно тем более гибкий материал

К о д





К о д

3M 707E

3M 747D 3M 777F

CU

CU

CU

JF

X

YF

CL

CL

CL

GA

GA

GA

R

R

R

Минерал Основа Покрытие Добавки Связка



24 36 40 50 60 80 100 120 150 180 220 240

3M 707E

3M 747D

3M 777F

Зернистость

Грубое шлифование Шлифование Полировка

Чем мельче зерно тем более гибкий материал



К о д



Выбор абразива: Шлифование

МеталлНержавеющая сталь

Никелевый

сплав

Углеродистая сталь

Алюминий Титан

3M 977F 3M 977F 3M 961F 3M 963F 3M 967F

3M 977F 3M 977F 3M 961F 3M 963F 3M 967F

3M 977F

3M 777F 3M 777F 3M 571F

3M 963F

Система быстрой

шлифовки

Backstand

С охлаждением,Бесцентровая

Минишлифлента



Инструментальная сталь 100N

174%

100%

114%

126%

0%

20%

40%

60%

80%

100%

120%

140%

160%

180%

200%

961F,TR46 464,AN3 977F, NI56 RX84

Абразивный материал

% И

знос

осто

йк

ость

961F,TR46 464,AN3 977F, NI56 RX84



Мягкая сталь 100N

161%

100%

0%

20%

40%

60%

80%

100%

120%

140%

160%

180%

961F, TR46 RX84Абразивный материал

% И

знос

осто

йк

ость

961F, TR46 RX84



Temperature Reduction



autom. backstand 29 m/s belt speedplunge grinding (bars 2,2x2,2 cm²) 3 mm/plungecontact wheel 65 Sh A; 2:1 80N force

flexible products on stainless steel- 3M vs. competition; grit 80, 80 N force -

0,0

20,0

40,0

60,0

80,0

100,0

120,0

140,0

160,0

180,0

200,0

to

ta

l sto

ck

rem

ov

al [%

]

0,0

0,5

1,0

1,5

2,0

2,5

1 11 21 31 41 51 61 71 81

number of parts

meta

l rem

ov

al ra

te [g

ra

ms/s]

stainless steel plunge grinding

product RB406 KK552JFF LS312 707E 907Egrit #80 #80 #80 #80 #80ctw 65Sh 65Sh 65Sh 65Sh 65Shinfeed 3mm/plunge 3mm/plunge 3mm/plunge 3mm/plunge 3mm/plungeforce 80 N 80 N 80 N 80 N 80 N

key points: - at medium pressures 3M 707F/3M 907F are superior to competition: more stock removal and faster cut - 3M 907F technically the very best



Идеальный контактный шкив для грубой шлифовки

Диаметр: small diameter50mmfor smaller scratches

Жесткость: 70-90 ед. по шору A

Насечки: 1:2

Угол насечек: 75O

Эластичность: высокая

например полиуретан



Effect of belt speed on cut

The higher the belt speed the higher the rate of cut. This is due to the fact that as the belt speed increases, more cutting edges are presented to the workpiece.

High

Rate of Cut

Low

Low Belt Speed High



Оптимальная скорость ленты для шлифования

Металл:

Алюминий

Углеродистая сталь

Никелевый сплав

Нержавеющая сталь

Титан

Optimum belt speed:

20 -25 m/sec

20 - 25 m/sec

25 - 35 m/sec

25 - 35 m/sec

10 - 15 m/sec



Effect of contact wheel area on pressure

The amount of pressure exerted against a workpiece will affect the rate of cut & belt life

The higher the unit pressure, the greater the stock removal

Contact Area

Plain Standard Scoop “Serr-x”

Groove to Land Ratio

1:1 3:1 4:1



What is TrizactTM?• Unique to 3M

• Totally new abrasive products

• Manufactured by microreplication (consistent

reproducible pattern)

• Use microstructured pyramid patterns of fine

grade minerals

• As minerals at top wear away, fresh new cutting

edges are exposed

• Possess greatly extended life







Trizact™ Structured Abrasives: Nothing outlasts the pyramids



Trizact™ Structured Abrasives life and finish compared to conventional abrasives

15 25

Parts Produced

Su

rfa

ce F

inis

h

201051

0,40

0,45

0,50

0,55

One belt

Belt 1 Belt 2 Belt 3 Belt 4 Belt 5

Coated Abrasive P400

Trizact A45



Trizact A45

Coated Abrasive P400

Total parts produced with one belt

Trizact™ Structured Abrasives:Nothing outlasts the pyramids







Trizact™ Structured Abrasives - Designed to save process costs by reducing the:

number of operations in a finishing process

downtime for changing belts

number of rejects

pressure required

operator fatigue

time for subsequent polishing, cleaning and plating operations



Trizact™ Structured Abrasive Belts

Product Code

3M 237AA

3M 307EA

3M 407EA

3M 243WA

3M 366FA

AO

AO

SC

AO

M

X

JE

J

X

X

660

660

660

660

1,320

Whatever the application, we have the best abrasive solution

Mineral Backing Max. Width mm



Grade Comparison

TRIZACT™ STRUCTURED

ABRASIVES

AVERAGE MINERAL

PARTICLES SIZE (mm)

FEPA P EQUIVALENT

GRITS

A6A16A20A30A40A45A60A65A80A90

A100A110A130A160

6162025303445506065707895

120

-1522263035465258666678

100120

P2000P1200P1000P600P500P400P320P280P240P220P220P180P150P120

Trizact™ Structured Abrasive



A160 A130 A110 A100 A90 A80 A65 A60 A45 A40 A30 A20 A16 A6

3M 237AA

3M 307EA

3M 407EA

3M 243WA

3M 366FA

Grade Range

Product Code


Trizact™ Structured Abrasive Belts



Product Selector: Refining

MetalStainless

SteelNickelAlloy

CarbonSteel Aluminium Titanium

3M 237AA3M 307EA3M 907E3M 977FRobot

Backstand

WetCentreless

Filebelt

3M 237AA 3M 307EA3M 907E3M 977F

3M 243WA3M 366FA3M 977F

3M 777F3M 707E

3M 237AA3M 307EA3M 907E

3M 961F 3M 217EA3M 227AA3M 963F

3M 407EA

3M 407EA3M 217EA3M 227AA3M 963F

3M 961F3M 237AA3M 307EA3M 907E

3M 243WA3M 366FA

3M 571F3M 777F3M 707E



Ideal Contact Wheel for Refining

Diameter: mediumdiameter200mm

Hardness: medium 40 - 65 shore A

Serration: 1:1Land to groove ratio

Serration Angle: 45O

Elasticity: medium

e.g. rubber



Factors Affecting: Refining

Optimising the application process and selecting the right abrasives: reduces total process costs

releases capacity

reduces rejects

reduces rework

saves labour costs

use the 3M Abrasive Process Cost Spreadsheet to calculate the true cost of your finishing process



Coolants and Lubricants:

Water (rust inhibitor) is the most effective coolant

Mineral Oil is the best for grinding steel and to prevent discolouration on non ferrous alloys

Soluble Oil improves the cutting rate on most metals and is less flammable

Grease reduces loading of softer metals and improves surface finish



Surface Roughness

The following table gives the average roughness in micrometer generated by each Trizact™ Structured Abrasive grade on various metals.



Ra micronRoughness Ra values may vary within a plus or minus 20% range depending on working conditions

Hard Chrome Plating

Tempered Stainless Steel

Tool Steel

Titanium

Stainless Steel 304

Carbon Steel

Brass

Copper

Nickel

Aluminium

A110

0.55

0.58

0.55

0.90

1.10

1.25

1.40

1.45

1.30

1.60

A100

0.50

0.53

0.53

0.65

1.00

1.10

1.20

1.25

1.15

1.40

A90

0.48

0.50

0.51

0.60

0.92

1.00

1.05

1.10

1.10

1.30

A80

0.45

0.47

0.50

0.50

0.85

0.90

0.95

0.98

1.00

1.20

A65

0.40

0.42

0.45

0.45

0.70

0.78

0.80

0.85

0.80

1.10

A60

0.34

0.36

0.40

0.40

0.60

0.70

0.75

0.80

0.65

1.00

A45

0.25

0.27

0.30

0.30

0.45

0.48

0.55

0.59

0.55

0.90

A30

0.15

0.17

0.20

0.25

0.29

0.35

0.38

0.39

0.40

0.65

A16

0.08

0.08

0.10

0.18

0.15

0.16

0.22

0.24

0.20

0.40

A6

0.03

0.04

0.04

0.09

0.06

0.08

0.09

0.10

0.12

0.30

The above values have been obtained statistically under the following working parameters:belt surface speed: 30 metres/secondsmooth rubber contact wheel: 40 shores Aworking pressure: 20.104Pa (2 kgf/cm2) feed speed: 4 metres/minute 2 passes

Surface Roughness





Trizact Customer Test Report

Notes/Actions

ResultsImproved Finish Reduced Production Time

YES NO * YES NOBelt Life

3M Trizact Structured Abrasives

Customer

Component

Material

Belt Size (mm)

Contact Wheel

Step Existing Method Parts/ Belts

TrizactParts/Belts

1 2 3456

Mops + Polishes

Blade Repair Shop

Turbine Blade

Nimonic (harder specs)

25 x 3350

P60 CoraP120 CoraP240 or A80

X X

TM

3-5 times

70 - 75

:* Acceptable finish

P80 3M977F

o(4.1) L : G

This sequence works well on some blades (e-flexed). Trizact has opened the doorat two sites. We are close to cracking all the business.

A160 3M237AA




Notes/Actions


YES NO YES NOBelt Life


Customer

Component

Material

Belt Size (mm)

Contact Wheel FELT BOBS


TrizactParts/Belts

1 2 *

3456

Mops + Polishes

UK Blade Manufacturer)

Wide Chord Fan Blade

Titanium

30 x 3350

Sometimes 60o Rubber 4 : 1 - L : G

GRINDING OPP100 CS 333P150 CS 333

P100 CS 333A110 3M407EA

* NB P100 3M977F ALSOON TEST

X X

1. P100 - Removes grinding marks & defects(sometimes P80 is used if condition of blade dictates).

2. P150 Finishes the blade:Trizact belts gave up to 10 TIMES the life ofthe P150. (RECTIFICATION & NEW BLADE WORK)

TM

6-10 x longer

TM




Notes/Actions




Customer

Component

Material

Belt Size (mm)

Contact Wheel Medium Hard


TrizactParts/Belts

1 2 *

3456

Mops + Polishes

UK Blade Manufacturer

Bar Blades (Various)

Titanium. Steel & Heat Treated St.

Slit to Various Widths) eg 25mm100 x 1830

MACHININGSTD P150 Belt (CS333 or RB406)

STD P400 Belt (RB406)

STD P150 BeltTrizact A45 (3M307EA)

* NB Cubitron on test.Results are looking v.gd

X X

1. P400 RB 406 STD Belt - useage of ONE or TWO Belts per blade

TM

(Felt with grooves cut in )

MACHINING

TM

TM

Av. 13 blades per belt

2. 3M 307EA Trizact A45 - Finished at average of THIRTEEN blades/belt - Across THREE types of material - VARIOUS blades

TM

CONSISTENTRESULTS FROM FOUR OPERATORS~ Trizact belt DOES NOT cut into RAD’sInstead it blends in and leaves NO marks. RB406 Belt - edge CUTS INTO radiuses.

TM




Notes/Actions




Customer

Component

Material

Belt Size (mm)

Contact Wheel


TrizactParts/Belts

1 2 3456

Mops + Polishes

Metal Finisher

Various

Mild Steel. Stainless Steel

75 x 1525

P120P180P240

A65A30

Sizal + Compo Bright Buff

X X

TM

3-4 times

Air Flow (Cotton)

P320P400

Sizal Buff

: Trizact belts lasted 3 - 4 times longer than Sia. Also 5 steps reduced to 3. A better finish was achieved with less operator effort. Mucheasier to buff up.

P120

TM




Notes/Actions


YES NO YES* NOBelt Life


Customer

Component

Material

Belt Size (mm)

Contact Wheel


TrizactParts/Belts

1 23456

Mops + Polishes

Dished End Manufacturer

Dished End

Stainless Steel

60 x 2250 (Farros Blatter m/c)

P60 = 2.8RaP80 NewP80 Used

A160 1.2-1.4 Ra

X X

TM

2 x

45 Shore Rubber 2 : 1 L : G

P120Scotch-BriteTM SCB

P60

o

A45 0.4-0.7 Ra

* reduction time 15-35 mins depending upon start time.2 dished ends finished with A160. A45 Trizact 237A Belt. NB Trizact belts were reversed after first dished end.

TM

TM



3M EUROPE & ME ASD FINISHING PROCESS COST CALCULATION TRLE2702 imp

Currency £ Sales Representative Component IP Compressor Blade Date 24 5 2000

Process data record STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 STEP 10 STEP 11 STEP 12

Product and grit Current process Comp. Comp. 456F 456F Comp. Mop/ Comp. Only fill blocks

P36 P60 P120 P320 P320 Compo 7SFN that are outlined

New process 977F 456F 456F 407EA DBWL in blue.

P40 P120 P320 A20 7SFN Current process

Belt price £ 0.95 0.95 0.14 0.14 0.95 17.50 New process

£ 1.50 0.14 0.14 1.76 17.50

Processing time minute 1.00 1.00 1.00 1.00 0.75 0.75 1.51 Click "ENTER" .

minute 1.20 1.20 1.00 0.62 1.00 Process Cost

Lifespan parts per belt 10 20.0 2 3 40 1000 is calculated

parts per belt 20 1 3 120 2000 automatically :

Rework or scrap rate % Labor cost £ per min 0.58 Number of parts produced per year

% Belt change time : minute 0.13 75000

Cost calculation per part, for each step : Total costsBelt cost 0.10 0.05 0.07 0.05 0.02 0.02 0.30

0.08 0.14 0.05 0.01 0.01 0.29

Processing cost 0.58 0.58 0.58 0.58 0.44 0.44 0.88 4.07

0.70 0.70 0.58 0.36 0.58 2.91

Belt change cost 0.01 0.00 0.04 0.03 0.00 0.00 0.08

0.00 0.08 0.03 0.00 0.00 0.10

Subtotal costs 0.68 0.63 0.69 0.65 0.46 0.44 0.89 4.44

0.77 0.91 0.65 0.37 0.59 3.30

Rework or scrap cost

Total processing cost £ 4.44

£ 3.30

Capacity increase 2425 hours per year Total saving 85550 £ per year Saving % % 25.68

Belt consumption per year 75700 104413



Three Dimensional Open Web

ResinAbrasive

Fibre

Scotch-Brite™ products: the brighter choice for surface conditioning



Spring Action

Abrasive Particles

Work Surface

Scotch-Brite™ products: the brighter choice for surface conditioning



Scotch-Brite™ surface conditioning products:

last longer

give consistent results

cut production costs

reduce waste and reworking



Scotch-Brite ApplicationsScotch-Brite Applications

Cleaning

Deburring

Finishing

Polishing

ASDTSTRG/BASIC/96-1



Scotch-Brite™ Surface Conditioning Belts

Product Code

SE-BS

SC-BS SC-BS

SC-BS

AO

AO

AO

AO

Brown/Blue

Brown

Maroon

Blue


Mineral Colour



Extra Coarse Coarse Medium Very Fine

SE-BS

SC-BS

SC-BS

SC-BS

Grade Range


Scotch-Brite™ Surface Conditioning Belts

Product Code



Scotch-Brite™ Unitised Wheels

Product Code

XL-UW S FN

XL-UW A MED

XL-UW A MED

XL-UW A FN

XL-UW A MED

XL-UW A CRS

SC

AO

AO

AO

AO

AO

Grey/Purple

Grey/Black

Tan/Red

Tan/Blue

Tan/Red

Tan/Red

2

2

6

6

8

8


Mineral Colour Density



Coarse Medium Fine

XL-UW 2S

XL-UW 2A

XL-UW 6A

XL-UW 6A

XL-UW 8A

XL-UW 8A

Grade Range

Product Code

Scotch-Brite™ Unitised Wheels




Product Selector: Finishing & Surface Conditioning

MetalStainless

SteelNickelAlloy

CarbonSteel Aluminium Titanium

3M 237AA3M 307EA3M 907E3M 977FXL-WLRobot

Backstand

WetCentreless

Filebelt

3M 237AA3M 307EA3M 977F3M 907ESC-BL

3M 243WA3M 366FA

SC-BS

3M 407EA3M 307EA3M 237AA3M 307EA3M 907EXL-WL

3M 407EA3M 307EASC-BL

3M 977F3M 907E

3M 237AA3M 307EA3M 977F3M 907ESC-BL

3M 243WA3M 366FA

SC-BSSC-BS



Ideal Contact Wheel for Finishing

Diameter: large diameter300mmfor longer scratches

Hardness: soft 20-35 shore A

Serration: plainLand to groove ratio

Serration Angle: 15O

Elasticity: low

e.g. cotton felt



Factors Affecting: Finishing & Surface Conditioning

The quality of the surface finish is influenced by a variety of factors as indicated below:

Belt Speed Belt speed affects the surface finish.

Contact Wheel Hardness The softer the contact wheel, the finer the finish.

Contact Wheel Diameter With all things being equal, the larger diameter contact wheel will produce the finer finish.



DEBURRING AND FINISHING WHEELS

Finishing Wheel (Blue Label)

Deburring Wheel(Red Label)

FS-WL

DB-WL



DeburringDeburringCompetitionCompetition

• Files, scrapers, wire brushes, mounted points, rotary burrs, carbide burrs

• Compared to these examples, 3M products– are faster– are safer– will not undercut or gouge the surface– will leave a better deburred surface



Deburring with Scotch-BriteTM Products

• Deburring of sides and surfaces• Advantages

– No secondary burr– Consistent radiusing of corners

(0.1-1.0 mm depending on the product and the way it is applied)

– No change in geometry of part– Maintains tolerance – Creates compressive stresses on surface



Surface finished with aScotchbriteTM Product

Surface finished with a conventional abrasive

Surface Finishes



Deburringwith WireBrush

Original Burr

Deburring with Scotch-BriteTM

Wheel

Deburring



Deburring with Coated Abrasive Product

Deburring with Scotch-BriteTM Wheel

Deburring

Technology

Абразивные материалы для металлообрабатывающей промышленности