How to choose polishing film for polishing different material ?
What is a polishing film?
Polishing film is a special type of multi-blade, multi-edge cutting tool. Its cutting function is mainly completed by abrasive particles adhered to the substrate. It consists of three elements: abrasive, binder, and base material.
What is an electrostatic sand-planting polishing film?
Electrostatic sand-planting polishing film uses high-voltage electrostatic field force and relies on the electrical properties of abrasives to implant fine abrasives on a cloth base, paper base, or high-strength film.
Why choose PET substrate?
As a carrier of abrasives and adhesives, the substrate is required to be firmly bonded to the adhesive and abrasives; have a certain degree of flexibility; have a certain strength and a small elongation; and have a flat surface. The substrates of coated abrasives are mainly: paper, cloth, non-woven fabrics, and polyester films.
The paper base has a fiber structure, which affects the flatness of the abrasive product; the abrasive particle size distribution is uneven, which is prone to deep scratches or insufficient grinding force. Moreover, the paper base has a low tensile strength and cannot be used as a polishing film. Generally, it can only be used as sandpaper.
The surface of PET polyester film is flat, and the prepared polishing film abrasive is evenly distributed, the tip is evenly upward, it is not easy to scratch the workpiece, and it can maintain uniform and continuous cutting force and the best surface accuracy; PET has high tensile strength and tensile strength, is water-resistant and heat-resistant, and can be used for dry and wet grinding.
The cloth base has a fiber structure, which affects the flatness of the grinding product; the abrasive particle size distribution is uneven, and the workpiece surface grinding accuracy is low; the cloth base will shrink and deform during wet grinding, which will affect the accuracy and consistency of polishing.
The advantage of electrostatic sand planting is that the abrasive particles are arranged in a directional manner, the product surface is sharp, and it can provide greater cutting force compared with conventional coated products.
The polishing film extends the working range of coated abrasives to the field of precision polishing, providing the possibility of micro-allowance and high-precision polishing. Film-based grinding products have been widely recognized in various precision processing industries. At present, precision polishing film have been widely used in industrial fields such as stainless steel parts, papermaking machinery, printing industry, copper foil industry, and can be used for precision polishing of shaft workpieces such as tungsten carbide rollers, ceramic rollers, chrome-plated rollers, and stainless steel rollers.
The precision polishing film uses film as the backing, adopts electrostatic sand planting, and the mineral sand converges to a normal distribution. The backing uses high-quality polyester film, which is extremely flat, providing consistent finish and uniform cutting performance. The mineral sand standard in microns is adopted, which is more consistent than the FEPA standard used by traditional coated abrasive products, ensuring the accuracy of the processed surface, providing consistent cutting, and effectively avoiding accidental scratches.
Traditional polishing films are mostly made of paper or cloth as the backing, and are produced by gravity sand planting or electrostatic sand planting. Generally speaking, traditional coated products are mainly used in metal structural parts, castings, forgings, etc., mainly for rough, semi-finished and fine processing. The requirements for workpiece size and roughness are not high, and closed belt grinding is usually used.
Thin polishing film extend the working range of coated abrasives to the field of precision polishing, providing the possibility for micro-allowance and high-precision polishing. The most important application occasions are camshafts and crankshafts of automobile engines.
As we all know, crankshafts and camshafts are the most critical components in the engine, so their precision requirements are very high. Any defects on the crankshaft and camshaft will seriously affect the performance of the engine. The shape profile and roughness of the crankshaft and camshaft are its key indicators.
Compared with paper-based and cloth-based products, this type of product has better precision, better water and oil resistance, and more lasting substrate strength and product strength, so it has a very wide range of applications in the field of precision grinding.
Advantages of electrostatic sand-planting polishing film
The abrasive of electrostatic sand-planting polishing film is sucked up by the electrostatic electric field force. The shapes of the abrasives are different, but the point of action of the electric field force acts on the center of gravity of the sand particles, so the big end of the sand particles faces inward, the small end and the pointed end face outward, and the big end is firmly glued to the film base by glue.
Therefore, the prepared polishing film has high grinding force, directional arrangement of particles, sharp product surface, and ensures the best grinding performance of the polishing film; the abrasive arrangement is consistent, it is not easy to scratch the workpiece, and it can maintain continuous and uniform cutting force and the best surface accuracy; it is water-resistant and oil-resistant, not easy to deform; it has a long life and good durability, and can be continuously and durable grinding to reduce production costs.
Electrostatic sand-planting polishing film can be used to polish various metal rollers, rubber rollers, etc.; in addition, it is used in the automotive manufacturing industry with huge market potential, which has two major parts: one is body processing, and the other is the final polishing of crankshafts, camshafts, and universal shafts.
The general shape contour is ensured by rough grinding of the grinding wheel, and its surface roughness is ensured by precision polishing film. Traditional processes use cloth-based polishing film for polishing, but the limitations of cloth-based polishing film are obvious. In addition to the above-mentioned disadvantages, they will shrink and deform when used in water-based cooling and lubricating fluids. Film-based products ideally avoid this problem and ensure part finish, roundness, geometric tolerances and dimensional control.
Moresuperhard electrostatic sand-planting polishing film uses high-voltage electrostatic field force to plant fine abrasives on high-strength films, so that the abrasives can be evenly distributed in a directional manner, providing higher grinding efficiency and bright and delicate mirror effects. Abrasive types include aluminum oxide, silicon carbide, diamond, etc. to meet the processing requirements of workpieces of different hardness.
Alumina oxide used for abrasives mostly refers to white corundum. White corundum is made of industrial aluminum oxide powder as raw material. It is made by high-temperature melting at more than 2000℃ in an arc and then cooled. It is crushed and shaped, magnetically separated to remove iron, and sieved into various particle sizes. It has a dense texture, white crystals, high hardness, and good cutting ability. It is suitable for grinding such as hardened steel, high carbon steel, stainless steel, alloy steel and tool steel.
Silicon carbide polishing film
Silicon carbide is made of quartz sand (SiO2) and stone tar (or anthracite) as the main raw materials, and is smelted at 2000~2200℃ in a resistance furnace. The main mineral component is α-SiC, which has higher hardness than corundum, but lower toughness, brittleness and sharpness. It is suitable for high-hardness alloy steel, materials with low tensile strength and high toughness such as brass and aluminum, and also for non-metallic materials such as plastics, rubber and resin plates.
Synthetic diamond micropowder is a new type of superhard abrasive, mainly used to manufacture tools used in industrial production for processing high-hardness and high-precision objects. It is used for grinding and polishing high-hardness materials such as cemented carbide, non-metals (such as gemstones, ceramics, optical glass), etc.
How to selection polishing film for polishing different workpiece?
Camshaft, crankshaft, gear shaft polishing | Electrostatic sand-planting aluminum oxide polishing film |
Stainless steel roll polishing | Electrostatic sand-planting aluminum oxide polishing film/Silicon carbide polishing film |
Mirror roll polishing | Electrostatic sand-planting aluminum oxide polishing film
60μm→30μm→15μm→9μm→1μm flocked polishing cloth The polishing effect can reach up to level 14 finish, Ra≤0.01μm |
Rubber roll polishing | Electrostatic sand-planting silicon carbide polishing film |
Gravure roll polishing | Electrostatic sand-planting aluminum oxide polishing film |
Cermet corrugated roller polishing | Electrostatic sand-planting diamond polishing film |
Cermet anilox roller polishing | Electrostatic sand-planting diamond polishing film |
—EDITOR: Doris Hu, Anna Wang
—POST: Doris Hu