Schleifmitteltechnologie Schleifwalze

Abrasive technology

Only with perfect tools optimal production processes are possible. And exactly for this goal develops boeck new tool solutions that set standards.

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01 Deslagging

During plasma or gas cutting, strong melting often occurs, with the molten metal sagging on the beam-exit side. This so-called slag occurs both on the inner and outer contours of the workpiece and must be removed for economical further processing.

Common manual methods for deslagging include chipping it away using a hammer and chisel, or grinding using an angle grinder. In terms of mechanical processes, excess accumulations of material can be removed by grinding with a soft contact roller. Another industrial method is knocking it off using a slag hammer brush made up of multiple flexibly mounted pins.

Schlackeentfernung Schleifmitteltechnologie

02 Pre-grinding & deburring

Burr formation on laser-, plasma- and gas-cut, or stamped, sheet metal parts often cannot be avoided. The burr respectively primary burr is a material formation on the cut edge of workpieces that protrudes beyond the original workpiece edges and surfaces. Other deviations from the target state include, e.g., spatters on the workpiece surface caused by laser cutting, unevenness, or scaling of the surface. A by-product of removing primary burr is the so-called secondary burr. This spreads out in the direction of the workpiece surface and forms due to insufficient removal and simultaneous recasting of the residue material.

Primary burrs, spatters, unevenness and/or scale layers are normally removed by grinding. When removing primary burrs, the focus is on minimising the formation of a secondary burr. In order to remove these undesired secondary attributes from the sheet without leaving a residue, special support units are required for grinding belts, -discs or -sheets.

Vorschleifen Entgraten Schleifmitteltechnologie

03 Deburring & edge-rounding

At this stage of the process, the primary and secondary burrs are removed and the edges rounded off. In order to lay the foundations for subsequent process steps (powder coating, wet painting, galvanisation, anodisation, bonding, etc.) and rule out any risk of injury due to sharp edges, the removal of the primary respectively secondary burr is often combined with the so-called edge-rounding. The edge rounding range from a few decimillimetres to radii of 2mm or even greater. These radii are now stipulated by standards such as e.g. DIN EN 1090.

The deburring and edge-rounding is carried out using flexible, abrasive tools with high adaptability to internal and external contours such as radii, boreholes and cut-outs. The corresponding deburring discs, deburring wheels, deburring blocks and deburring brushes are used on portable machines as well as grinding and deburring machines. The last mentioned machines have, for example, planetary head systems or oscillating units for uniform processing of the edges.

Entgraten Verrunden Schleifmitteltechnologie

Interdependencies

Larger edge rounding requires more removal. However, there is no linear relationship between edge radius and removal. For example, the removal rate quadruples when the radius is doubled.

grafik wechselwirkungen beim entgraten

04 Oxide removal

Oxygen-cut workpieces have oxide layers on the cut edges. These „dark layers“ pose a risk for subsequent processes and can lead for example to chipping of the coating. For that reason they must be removed.

Mechanical removal of the oxide layer is achieved by grinding or brushing. Both processing options can be implemented for manual processing procedures. In terms of mechanical processing, it is mostly brushes that are used, which, thanks to a specially developed wire fill in an innovative multi-row arrangement, flexibly follow the contours of the workpiece and achieve blank metallic edge surfaces.

Oxidentfernung Schleifmitteltechnologie

05 Finish-grinding

The purpose of this process step is to grind out scratch marks and create a decorative surface. Specific grinding patterns right up to a high-gloss mirror finish can be achieved on the sheet metal surfaces.

During the last processing step, it is primarily abrasive cloth, nonwoven abrasive, and felting tools that are used, as a continuous belt or roller. With manual processing techniques, the results, and their reproducibility, depend heavily on the operator. For mechanical finishing, the machine must have appropriate setting options.

Finishschleifen Schleifmitteltechnologie