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PRAXIS
In the modern world, stainless steels are finding their way into an increasing number of applications. Their outstanding properties, e.g., high resistance toughness have given rise to a broad variety of uses. In addition, new grades of these materials are being developed continuously for specific needs. Today, stainless steels have become indispensable in a broad range of industries and applications including chemical and petrochemical equipment. foodstuff processing vessels and machinery. process technology. pulp and paper processing. architecture (building fronts, handrails). power plant engineering. pump and turbine manufacturing. shipbuilding (piping, containers). structural and mechanical engineering. The particular characteristics of stainless steels impose specific requirements on the machining and finishing tools used. Thus, most austenitic steels are more difficult to machine than their unalloyed counterparts due to their stickiness, edge build-up tendencies, and strain hardening behavior. On the other hand, the eco-friendliness of stainless steels - as expressed in their durability, corrosion resistance even when uncoated, and recyclability - is a factor that has contributed not least significantly to their ever more widespread use.
"Stainless steel" is a collective term covering over 120 different steel grades which share the following properties:
They are alloyed with at least 10.5% chromi-
um.
They are corrosion-resistant without any pro-
tective coating, forming an invisible surface passivation layer in the presence of oxygen. 1. The thermal conductivity of austenitic steels is lower to that of other steels (and most stainless steels are of the austenitic type). As a result, the heat generated by the rotating tool is not easily dissipated via the workpiece or the chips. 2. Cutting speeds should be kept lower than with other steels, regardless of the machining process used. The tool should not be applied with excess pressure. Local overheating may cause discoloration or distortion of the material, and thermal overloading of the tools would be a likely result. 3. Abrasives designed for use on stainless steels must contain no elementary iron, which might form corrosive deposits in the workpiece. Similarly, to avoid such "extraneous" rust, a tool previously used on non-stainless steel should never be used on stainless grades. 4. Chip particles from the workpiece ("sparks") may be transformed into non-stainless steel at the high temperatures developed during machining. Unless such particles are carefully removed, they too will cause extraneous rust on the workpiece surface. Thorough chemical and/or mechanical cleaning (by etching, pickling, polishing, etc.) is therefore indispensable to protect stainless steel from extraneous surface corrosion. As long as such cleaning is carefully performed and the workpieces are kept away from non-stainless grades, the formation of extraneous rust on stainless steel is virtually impossible.
PFERD offers an extensive range of tools meeting the specific requirements of the stainless steel processor. Many of these tools were purpose-designed for this application; all have been found to give good results in everyday practice. In addition, PFERD provides free applicationrelated advice on all machining issues involving stainless steels - without any obligation on your part. Our experienced field staff and technical customer service engineers will be glad to be of help. So why not give us a call? All of these tools are free of elementary iron, sulfur, or chlorine.
Stationary cutting
Stationary machines are employed, e.g., for cutting solid material, billets, pipes, and sectional products. This abrasive cutting technique is often used in volume production environments. Suitable PFERD tools: Abrasive cut-off wheels up to 1250 mm dia. Refer to page 5.
Freehand cutting
Used on sheet metal, sectional products, pipes, and solid material. Suitable PFERD tools: Abrasive cut-off wheels in the 30 - 300 mm dia. range Refer to page 5.
Stage 1 This very rough surface can be produced with the tools listed at right:
Tools for Stage 1 Depressed-center grinding wheels POLIFAN flap discs Fiber discs Abrasive spiral bands Fan grinders Flap wheels COMBIDISC abrasive discs COMBIDISC Mini-POLIFAN discs Mounted points ADW/AWN/AW/AN, hardness grades I/H/L/M/N
This satin-finish surface can be produced with the tools listed below:
Satin-finishing tools POLINOX points, wheels and rolls, PNL/PNR/PNZ/PNL types (aluminium oxide or SiC) POLINOX foamed ring wheels PNK Power Brushes
Stage 2 This rough surface can be obtained with the tools listed at right, starting out from a Stage 1 finish:
Tools for Stage 2 POLIFAN flap discs Fan grinders Flap wheels COMBIDISC abrasive discs COMBIDISC Mini-POLIFAN discs COMBIDISC POLIVLIES discs (hard type) POLIVLIES discs, PV type POLIVLIES hook-and-loop discs POLICLEAN tools Mounted points (ADW bond type) Tools for Stage 3 Poliflex fine grinding points with GH, GHR, PUR and TX bond Poliflex fine grinding wheels with GR and PUR bond Poliflex blocks POLIVLIES abrasive spiral bands, hand pads INOX brushes / SiC brushes Fan grinders Flap wheels COMBIDISC abrasive discs COMBIDISC non-woven abrasive discs (soft) POLINOX points PNL, PNR, PNG, PNZ POLINOX ring wheels / rolls
This marbled surface can be produced with the tools listed below:
Marbling tools Poliflex marbling tools Marbling tools carrying non-woven abrasive discs
Stage 3 This fine surface can be produced using the tools listed at right, starting out from a Stage 2 finish:
This matt-finished surface can be produced with the tools listed below:
Matt-finishing tools POLINOX points, wheels and rolls POLINOX foamed ring wheels PNK Poliflex mounted points, PUR bond
This cleaned surface can be obtained with the tools listed below:
Stage 4 This very fine surface can be produced using the tools listed at right, starting out from a Stage 3 finish:
Tools for Stage 4 COMBIDISC non-woven abrasive discs (soft) COMBIDISC felt discs with grinding compound / diamond polishing paste Cloth rings, used with bars of polishing paste Felt points with and without metal insert, in conjunction with grinding compound or diamond polishing paste
Cleaning tools POLIVLIES abrasive spiral bands INOX brushes SiC brushes POLINOX points, wheels and rolls COMBIDISC non-woven abrasive discs (hard type) POLICLEAN non-woven abrasive tools
SG-PLUS-INOX types Special high-performance cut-off wheels with an outstanding service life. SG-INOX types Special-purpose cut-off wheels for a broad range of cutting tasks. Various wheel widths, from 1.6 to 3.2 mm, permit an optimum adjustment to the specific application and machine output. PS-FORTE-INOX types General-purpose cut-off wheel for universal use.
SG-PLUS-INOX types The ultimate in quality and performance. For quick, professional results and unsurpassed durability and cost-effectiveness. SG-INOX types High-performance cut-off wheels for rapid cutting, convenient to use and long-lasting. PS-FORTE-INOX types For general purpose use, specifically on thinwalled materials.
Abrasive cut-off wheels for stationary machines are listed in our Catalogue 206.
For extra thin freehand cut-off wheels refer to our Catalogue 206.
Fiber discs
Fiber discs are highly flexible abrasive tools used for fine surface grinding tasks. Their flexibility makes them particularly useful for grinding on contoured workpieces. The stock removal rate can be varied via the hardness of the backing pad. Z types For maximum stock removal in surface and edge grinding. Optimum contact pressure is achieved with a H-GT type hard backing pad. Ceramic grain types These tools provide aggressive grinding action with outstanding stock removal, producing a fine ground finish. Hook-and-loop abrasive discs and holders Abrasive discs for hook-and-loop attachment to the backing pad are used mainly in fine-grinding of large, level surfaces. Special benefits: Flexibility. Easy-on, easy-off disc change. Aluminium oxide A types are available in 6 grit sizes.
HM - Cut 1 (according to DIN C) Materials: For soft stainless steels. Applications: Deburring, coarse fettling work. Weld finishing. Properties: High stock removal. Suitable for higher speeds.
Form ZYA
Form WRC
Form SPG
Form KUD
Form SKM
Form TRE
Features
1. The tungsten carbide material and recommended cut geometries of these tools are optimized for use on stainless steel. 2. PFERD tungsten carbide burrs are particularly wear-resistant and durable; they can also be re-ground. As a result, these products provide smooth and uniform stock removal (nick-free cutting edges provided). good chip removal. quiet, chatter-free operation. convenient tool control and reduced operator fatigue. high surface qualities. 3. In certain cases, tungsten carbide burrs can be supplied with a coating which protects against abrasive wear while reducing the heat load on the workpiece (refer to HICOAT coatings). Recommended cutting speeds: Cut 1 300-450 m/min Cut 3 250-350 m/min Cut 3 PLUS 250-350 m/min Cut 4 250-350 m/min Non-standard cuts and custom shank lengths and diameters are available upon request. HM - Cut 3 (according to DIN MY) Materials: For high-strength stainless steel, stainless steel castings. Applications: Deburring (including robotized operation) Chamfering. Properties: Cut without chip breaker. Provides score-free surfaces.
HM - Cut 3 PLUS (according to DIN MX) Materials: For medium-strength stainless steels. Applications: Fettling. Surface finishing. Weld reworking. Geometry adjustments. Properties: Universally suitable. Provides level, smooth surfaces. Smooth operation. High stock removal. Short chips, non-loading.
HM - Cut 4 (according to DIN MY) Materials: For hard, high-strength stainless steels. Applications: Edge and surface work, geometry adjustments. Use on welded claddings. Properties: Double-fluted to minimized axial forces. High chip removal. Smooth operation. Non-loading.
Mounted points
For freehand weld grinding, pre-finishing, smoothing, deburring and chamfering work. PFERD mounted points are noted for the following features: Powerful grinding action. Long service life. Optimum concentricity. Easy to profile. Ceramic bond: Bond Hardness Properties AWN H soft grinding action, good abrasive performance AW I fast stock removal, reduced heat build-up ADW M versatile generalpurpose tool Resinoid bond: Bond Hardness Properties ADW L high abrasive performance, reduced heat build-up, particularly suitable for stainless steel AN N high abrasive performance, reduced heat build-up, long service life, particularly suitable for stainless steel
Fine-Grinding Tools
POLIROLL
These cartridge rolls are used for leveling in hard-to-reach areas. They are suitable for use on steel, including stainless grades. As the outer layer wears off, fresh grain is exposed in successive layers. The product thus provides very good stock removal properties. The self-locking action on a grooved conical arbor permits fast tool changes.
A type (aluminium oxide) Available in six roll widths and 10 finely graded grit numbers (36 - 800).
For storage and convenient dispensing, our range includes a single-roll holder (SRH 1) as well as a multiple-roll holding unit (SRH 5). Both holders are prepared for easy wall mounting.
For abrasive spiral bands and associated rubber holders refer to our Catalogue 204.
Arbor Bo PFF
AF 14-1/4
Zirconia Alumina Z types Achieve outstanding stock removal rates when used in conjunction with a hard backing pad. Aluminium Oxide A-Forte types General-use products, specifically suitable for tough materials. High abrasive performance, long service life. Aluminium Oxide A-INOX-Forte types Designed specifically for heavy duty applications involving difficult-to-work materials. Active fillers improve stock removal performance while reducing heat build-up. Ceramic Grain CO types For aggressive abrasive action with maximum stock removal, achieving a fine surface finish. A-PLUS types Preferably for edge grinding work. CDR system
Zirconia alumina Z types Achieve outstanding stock removal rates when used in conjunction with a hard backing pad. Aluminium Oxide A-INOX-Forte types Formulated with active filler material for improved material removal and reduced heat build-up. Aluminium Oxide A types For general-purpose grinding applications.
CD system
ATADISC system
For COMBIDISC Mini-POLIFAN discs refer to our brochure "New in the PFERD Range".
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Fine-Grinding Tools
Fan grinders
The laminae holding the abrasive grain are arranged like a fan around the shaft of these tools. Depending on contact pressure and operating speed, fan grinders can achieve high stock removal rates or, alternatively, produce very smooth surfaces with reduced material removal. The operating speed limits imposed for safety reasons lie comfortably above the optimum speed for most grinding applications. The slit laminae of the fan grinder brushes adapt easily to both concave and convex workpiece contours. Diverse roughness levels required for functional or visual reasons can thus be easily produced. A-INOX types Designed specifically for stainless steels and high-temperature alloys, these grinders combine high stock removal rates with nonloading performance. Silicon Carbide C types The high hardness and sharpness of SiC grain minimizes thermal loads, thus avoiding heat build-up and cracking in high-alloy steels.
Flap wheels
Flap wheels can be used in conjunction with high-powered drive units to remove coarse surface irregularities (e.g., in weld dressing). They are principally designed to produce homogeneous finishes on larger surfaces and contours by freehand grinding (i.e., matt finishing). Used at the right speed, these tools can create an extra-fine surface finish that is an ideal starting point for subsequent polishing or buffing operations. They are likewise suitable for robotized processes and stationary machines. In the newly designed mounting system the flanges are fully recessed in the flap wheel. This is advantageous inasmuch as the wheel face can be brought up almost flush against the material when working near edges or corners. A-INOX types For efficient grinding on stainless steel, from coarse to fine. The abrasive performance of the flap wheel is greatly enhanced by active fillers. A types Suitable for universal fine-grinding applications on stainless steel grades.
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Non-Woven Abrasives
Aluminium Oxide A - hard types Available in coarse, medium and very fine grit sizes. Aluminium Oxide A - soft types Available in coarse, medium, fine and very fine grit sizes.
Aluminium Oxide A types Grit sizes 100, 180 and 280. The material is oil resistant and waterproof.
POLIVLIES hand pads in Aluminium Oxide A and SiC abrasive grades are ideal for manual cleaning jobs and removal of score marks. For hand pads refer to our Catalogue 204.
POLIVLIES finishing rolls with Aluminium Oxide A abrasive grain are an alternative to hand pads. For more detailed information refer to our "Flexible Abrasive Products" brochure.
For use on belt grinders, PFERD offers these POLIVLIES surface conditioning belts made of a non-woven fiber mesh on tough web backing. For more detailed information and matching belt grinders refer to our Catalogue 209.
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Non-Woven Abrasives
For POLINOX abrasive rolls refer to our "New in the PFERD Range" brochure.
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POLICLEAN tools
With their unique combination of high abrasive performance and durability, POLICLEAN tools are ideally suited for diverse surface conditioning tasks, e.g., cleaning, grinding, deburring, and texturing. They are used chiefly in removing scale and surface discolorations from stainless steel workpieces. POLICLEAN wheels For general-purpose circumference grinding, offering easy handling and quick tool changes (the wheel can be replaced without removing the arbor from the collet). Wheel diameter range: 50 - 150 mm Up to 3 wheels can be stacked on a special arbor. Abrasive material: silicon carbide COMBIDISC POLICLEAN tools Offering outstanding face grinding performance, these tools ideally supplement the COMBIDISC range. Diameters: 50 and 75 mm. POLICLEAN Disc Unmounted abrasive disc on a glass-fiber backing pad. Diameter: 115 mm. For grinding large surfaces, mainly with speedcontrolled angle grinders.
POLINOX star pads For cleaning, deburring and fine-grinding of surfaces and contours, especially in confined areas such as bores, recesses, and hard-toreach corners. Mounts on 6/13 1-25 special arbors. Grades: medium, fine, very fine Abrasive material: aluminium oxide
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Cloth rings
Cloth rings are used in conjunction with polishing pastes to obtain very fine surface finishes, up to mirror-polished quality. Fields of application: Polishing of hollow ware and profiled products, e.g., faucetry. Mechanical engineering, process equipment construction. Builder's hardware industry. Cutlery manufacture. For pre-polishing Use cloth grades ST (sisal) and TH (hard) with polishing paste PP1VP (green). For de-polishing Cloth grades TW (soft) and FL (flannel) with polishing paste PP4HGP (pink). Recommendation Do not mix polishing pastes. Use only one paste type on a given cloth ring.
Felt tools
Felt points, wheels and discs are designed mainly for high-gloss polishing applications. Felt points with metal inserts are used for more aggressive pre-polishing with diamond polishing pastes. For pre-polishing: Felt points/wheels with metal inserts (brass wire), in conjunction with diamond polishing pastes For fine-finishing: Felt points in various head shapes and dimensions, used with diamond polishing paste. Felt points can be profiled using a dressing stone. Felt discs (mainly for stationary machines), in combination with diamond polishing paste. COMBIDISC felt discs for face-on polishing in conjunction with diamond polishing pastes.
Poliflex fine-grinding points ANCN-TX (TX bond) For pre-grinding, light deburring, and edge breaking work on hard edges. AWCN-LHR (hard leather bond) Highly wear and edge resistant. AW-LR (leather bond) For high-grade surface finishing, pre-polishing, and edge breaking. ANCN-GHR (hard rubber bond) For fine-grinding with elevated stock removal rates. AR-GR (rubber bond) For soft fine-grinding and pre-polishing. CN-PUR (polyurethane bond) Very soft and flexible, particularly cool grinding characteristics.
Poliflex Disc
Diamond polishing paste in four grit sizes, from D30 (coarse) to D3 (very fine)
For cloth rings and polishing pastes refer to our Catalogue 204.
For felt tools and polishing pastes refer to our Catalogue 204.
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Set of test tools for use on stainless steel in an attractive hard case
Basic stainless steelworking tool set, comprising a selection of versatile fan grinders and POLINOX tools. Contains: Electric straight grinder UGER 5/90, electronically speed controlled from 4000 to 9000 r.p.m., output 500 W. 2 fan grinders and 10 POLINOX mounted points in diverse types and grit sizes.
Contains: Angle grinder with COMBIDISC tools for diverse stainless steel finishing tasks, from coarse to mirror-polished. 1 electric angle grinder UWER 5/200 Si, electronically speed controlled (9000 - 20000 r.p.m.), output 500 W. 4 disc holders + 2 arbors for alternative tool drives. Various abrasive discs, TX discs, COMBIDISCMini-POLIFAN tools, non-woven and felt discs (50 mm dia.). Polishing paste (bar type) for use on felt discs.
August Rggeberg GmbH & Co. KG PFERD-Werkzeuge Hauptstrae 13 51709 Marienheide Phone 0 22 64/90 Fax 0 22 64/ 94 00 Intl Sales 94 88 www.pferd.com pferd@rueggeberg.com
PFERD quality certified according to EN ISO 9001.