Factors Affecting the Service Life of Sanding Belts

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The production process of abrasive belts demands strict requirements for the base material,  abrasives,  bonding agent,  and grit density. Premature wear and tear of abrasive belts often result from improper usage.

1. Clogging:

Clogging occurs when a layer of metal material covers the cutting edges of abrasive grains,  causing the surface of the abrasive belt to become shiny and slippery. This issue predominantly arises with high-strength metals, particularly hard materials.

-Insufficient grinding pressure is the primary cause of clogging. For high-hardness materials,  inadequate pressure makes it challenging for abrasive grains to penetrate the workpiece and self-sharpen.

-The use of relatively soft contact wheels or pressure plates can cause excessive collapse,  hindering the penetration of abrasive grains into the workpiece.

-High abrasive belt speeds result in insufficient time for abrasive grains in the grinding area,  leading to reduced cutting depth and increased heat generation.

To address clogging,  a comprehensive approach is necessary. This includes the use of suitable contact wheels or pressure plates,  adequate grinding pressure,  and lower abrasive belt speeds. Additionally,  selecting abrasives with excellent self-sharpening characteristics is crucial.

2. Dull Abrasion:

Dull abrasion occurs when abrasive grains in the grinding process retain their presence but lose their sharpness. This phenomenon signals the end of the abrasive belt's service life. However,  in this context,  "dull abrasion" refers to cases where the abrasive belt's selection or usage is improper,  leading to premature wear.

-Soft contact wheels or pressure plates can hinder abrasive grains from penetrating the workpiece,  causing the cutting edges to wear down.

-Insufficient grinding pressure can also dull the abrasive belt,  preventing abrasive grains from self-sharpening effectively.

-Unsuitable abrasive belt selection for hard workpieces or excessively high belt speeds can result in inadequate cutting penetration,  leading to dull abrasion.

Abnormal abrasive wear significantly affects the service life of abrasive belts,  increasing processing costs,  and should not be overlooked.

3. Clogging:

Clogging occurs when the gaps between abrasive grains become quickly filled and obstructed with debris,  even before the cutting edges of the abrasive grains have been fully dulled. This phenomenon renders the abrasive belt incapable of cutting efficiently.

Clogging can be caused by various factors,  including improper usage,  workpiece material,  and abrasive belt selection:

-Using soft contact wheels or pressure plates may lead to a grinding-dominated state,  generating frictional heat that welds debris to the abrasive belt,  causing clogging. To address this,  employing hard contact wheels and pressure plates or utilizing peak-toothed contact wheels and pressure plates is recommended.

-Excessively high abrasive belt speeds can also hinder effective abrasive grain penetration,  leading to clogging and workpiece burn. In such cases,  reducing the abrasive belt speed is necessary.

-Softer materials,  such as non-ferrous metals like aluminum and copper,  are highly prone to clogging the abrasive belt surface. Solutions include using sparse abrasive belts,  selecting coarser-grit belts within the specified roughness requirements,  using silicon carbide abrasive belts with higher brittleness,  and employing grinding additives such as lubricants.

For smooth surfaces of work-pieces prone to clogging,  abrasive belts with excellent chip evacuation and anti-clogging properties,  such as coated abrasives with super coatings,  should be considered.

Proper understanding and control of the factors that affect the service life of abrasive belts are crucial for achieving high-quality results and maximizing their efficiency. By selecting appropriate contact wheels,  pressure plates,  and abrasive belts,  along with maintaining adequate grinding pressure and speed,  users can extend the service life of abrasive belts and optimize their grinding processes. Additionally,  a comprehensive approach to addressing issues like clogging and dull abrasion will contribute to increased productivity,  reduced costs,  and improved overall performance in abrasive belt applications.