Save time and money by optimizing cutting wheel selection

Companies can save money in a pipe welding operation in many ways. It&#;s difficult or perhaps impossible to cut back on fixed costs or labor, so reducing the costs of consumables, such as cutting and grinding wheels, often is the primary target. However, this can lead to inefficiencies, and it&#;s easy to overlook the hidden costs. From reducing downtime to improving productivity, many operators realize in many cases that buying higher-priced, high-performance cutting and grinding wheels ultimately provides the lowest overall cost of use.

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Selecting the proper cutting wheel for the job and following best practices for its use can lower costs by reducing the amount of filler metal needed to produce a quality weld, decreasing rework, and prolonging the effective cutting life of the wheel. In addition, it can minimize labor and downtime for wheel changeover.

Good Preparation Leads to Good Welds

Any good weld is the product of good, thorough preparation. Preparing a joint that is smooth and uniform results in a clean, strong weld. Wide or uneven joints require additional filler material, which usually is the most expensive consumable associated with welding. Poor joint preparation can lead to additional passes and can result in welds that are structurally weak and not very aesthetic.

The type of material being cut is one of several factors to consider when choosing a cutting wheel. Common materials used in tube and pipe applications include mild steel, chrome-moly steel, stainless steel, titanium, INCONEL® alloy, and aluminum. When cutting stainless steel and aluminum, choosing a wheel that is rated contaminant-free (inox, from the French word inoxydable) is important. These materials commonly are used in the food service and medical industries.

A critical question concerns versatility. Are you always working with the same material, or do you work with several material types? Do you need to purchase several products, or do you need a one-size-fits-all option?

Cutting Wheel Materials

The pipe&#;s outside diameter and wall thickness dictate the most appropriate tool size. Consider these common tool sizes and the recommended maximum cutting diameters when selecting a cutting wheel:

• 4.5-in. grinder: up to 3&#;4-in. OD
• 6-in. grinder: up to 21&#;2-in. OD
• 7-in. grinder: up to 3-in. OD
• 9-in. grinder: up to 31&#;2-in. OD

While it is possible to cut larger-diameter pipe with smaller-diameter wheels, remember the importance of a perfectly clean, straight seam to prepare for the weld. A wheel diameter that will cut straight through the pipe&#;s diameter will produce the most even cut line and weld seam.

Grain type is the next consideration. Three cutting grains commonly used in bonded abrasive cutting wheels are aluminum oxide, zirconia alumina, and ceramic alumina.

&#; Aluminum oxide. Aluminum oxide wheels use soft bonds that aren&#;t too resistant to heat, resulting in a cut that is fast, smooth, and easy to control. However, this type is the least durable of the three.

Aluminum oxide wheels are the least expensive and have a high initial cut rate, but the tradeoff is a short product life. As a result, aluminum oxide is suitable for cutting mild alloys such as carbon steel and is a good choice for cutting thin gauges and doing repair work, but it is not considered the best option for cutting harder or more exotic metals.

&#; Zirconia alumina. Zirconia alumina is harder and tougher than aluminum oxide, so it maintains sharpness and lasts longer than aluminum oxide. Its increased toughness makes it more heat-resistant, and it can be used with harder bonding materials, resulting in a wheel that cuts faster and lasts longer than an aluminum oxide wheel. A zirconia alumina wheel comes at a higher cost than an aluminum oxide wheel, but it gets the job done quicker with fewer changeovers. The result usually is a lower overall cost of use.

&#; Ceramic alumina. Ceramic alumina grains fracture and self-sharpen through the cutting process and are very durable. As a result, ceramic alumina wheels maintain sharpness and cut rate for roughly 75 percent of their lifespan before an operator feels a decrease in cutting performance. Ceramic wheels have the highest initial cost but arguably have the lowest long-term cost.

Because ceramic grains need to fracture to maintain sharpness, tool speed is important. Using a ceramic alumina wheel with an underpowered tool can prevent the operator from realizing the full value of the grain. The ceramic alumina grain can cut most material types.

A thicker-than-necessary wheel generates excessive heat and friction, which are the enemies of any cutting wheel and can greatly affect wheel life. Prolonging wheel life is a matter of minimizing the surface contact to reduce friction and heat; to minimize surface contact, choose the thinnest possible wheel that will get the job done.

Reducing Overall Costs

In small shops that focus mainly on carbon steel, thin gauges, or repair work, an inventory of aluminum oxide cutting wheels might be the way to go. However, as the shop size increases&#;and the distance from work cells to the tool crib gets longer&#;and the mix of alloys grows more complex, zirconia alumina or ceramic alumina might make more sense. They help to combat the hidden costs associated with changeovers and inventory.

First, while, cutting as fast as possible is an obvious benefit to productivity, cutting as long as possible is perhaps just as critical. A 30-second wheel change can be costly when it involves a lengthy walk to the tool crib. Time studies have shown that a wheel change can take up to 40 minutes. If each operator changes wheels four times per day, the downtime amounts to 30 percent of a shift.

In such a case, a ceramic alumina wheel has a significantly lower overall cost of use than an aluminum oxide wheel. While the ceramic wheel costs more initially, it cuts much faster and lasts longer, requiring less frequent changeover, minimizing downtime and improving labor productivity.

Second, when working with a variety of materials and using several cutting wheel types, inventory management and related costs also are concerns. Keeping two or three cutting products in inventory gives the operator the maximum number of choices, but purchasing cutting wheels in three types and four sizes is a minor headache. Buying only ceramic alumina, which can cut anything, simplifies purchasing, storing, and resupplying this consumable.

Best Practices Can Save Money

Cutting technique affects wheel performance. The important factors involve pressure, friction, and vibration.

First, let the wheel do the work. Don&#;t plunge the wheel all the way through the workpiece, and don&#;t push too hard on the wheel, which causes the speed to drop. Zirconia alumina and ceramic alumina grains work best at high speeds.

Second, minimize surface contact and friction as much as possible. This reduces heat, which ultimately allows for the wheel to cut faster, smoother, and cleaner. Heat also breaks down the wheel faster, so a cooler cut prolongs wheel life. Before starting the cut, hold the wheel next to the tube or pipe to better understand how deep the cut should be. The depth of the cut is dictated by the thickness of the metal. Use consistent motion through the cut without pushing or plunging. Using motion rather than pressure to perform the cut minimizes friction and heat.

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Third, minimize vibration by performing the cut as close as possible to the mounting or clamping point while still allowing adequate clearance for hands, the cutting tool, and the guard. The greater the distance from the clamping point, the more vibration translates through the workpiece into the wheel, which causes premature breakdown or potential failure.

For a given grinding, blending, or finishing task, choosing the proper disposable flap disc reduces the chance of removing too much material and assures an optimal finish. Here are a few important considerations to take into account while selecting the best instrument for the job in order to maximize flap disc effectiveness and longevity.

For metal grinding or finishing tasks, using the appropriate equipment can save time and money. The greatest option can reduce the chance of eliminating too much material and provide the best finish. Particularly, flap discs allow fine blending and finishing operations while providing dependable grinding action. They are a flexible and effective option for many applications, even those utilizing thinner materials, because of these characteristics.

Flap discs use the same grain types as bonded abrasive cutting, grinding, and combination wheels, but their layered flap design gives them a softer, more forgiving feel. Because of this, flap discs can be used for grinding and finishing without switching to another product or disc. There are a number of important factors to think about in order to select the best flap disc for the job and to maximize product efficacy and longevity:

• What kind of substance is being worked on?

• What are the demands for a surface finish and the ideal appearance of the finished piece?

• Are there requirements for the task in terms of time, output, and efficiency?

• What are the associated labor and supply costs?

BASICS OF FLAP DISC

Flap discs make use of coated abrasives that hold grains to a backing fabric. The fabric, which is frequently cotton, polyester, or a combination, is then divided into smaller flaps and stacked to create the flap disc. The flaps wear away as the grains exhaust and lose their cutting effectiveness, revealing new, acute grains underneath. Flap discs can be used effectively until the cloth is almost worn all the way to the back plate. For use on right-angle grinders at angles ranging from 5 degrees to 35 degrees, flap discs are intended.

Flat-profiled Type 27 flap discs are ideal for finishing and applications that call for lower grinding angles, such as 5 to 15 degrees. Type 29 flap discs are suitable for more vigorous, higher-angle grinding since they have a slight slant. Since a flap disc's fabric can catch or tear in these really intense grinding situations, hard grinding discs may be a preferable option when the work requires more aggressive action or grinding on rougher surfaces.

GRAIN OPTIONS AND DISC SIZE

Consider the specifications of the finished weld while selecting the right grain for the operation. Keep in mind that the grit is coarser and more aggressive, the lower the number. Larger grit sizes are less abrasive, finer, and offer better finishes. To get the greatest finish, use the highest grit that can be used while still getting the job done. Flap discs are also offered in high-density and standard-density varieties.

The disc size options range from 2 in to 7 in, and 2 in and 3 in flap discs can frequently replace a blending disc and provide up to 15 times the use, reducing the number of product changeovers, increasing productivity, and significantly lowering the overall cost of use. High-density durable flap discs are a great option for grinding on curved or irregular surfaces.

SELECTION OF THE ABRASIVE MATERIAL

The type and grit size of the abrasive substance employed have a significant impact on the performance of the disc. Aluminum oxide, zirconia alumina, and ceramic alumina are the three main grains used. The objective is to identify the flap disc that completes the application's requirements within the desired schedule and budget. Aluminum oxide is a reliable, affordable product alternative, although zirconia alumina flap discs frequently provide the greatest adaptability for the least amount of money spent. Zirconia alumina flap discs are the most widely utilized flap discs nowadays.

Zirconia alumina flap discs come in different quality levels. A combination of zirconia alumina and aluminum oxide grains is one less expensive approach. 100% zirconia alumina grains are another high-performance option. These discs don't degrade as quickly and keep their cut-rate for a longer period. Aluminum oxide flap discs are slightly more expensive than standard and high-performance items up front, but they have better heat resistance, toughness, and durability.

High-performance flap discs should be kept in mind as they are more expensive. Still, they can offer a much reduced overall cost of use by minimizing changeovers, reducing downtime, and enhancing productivity. Ceramic alumina, the most expensive but also the most durable and heat-resistant abrasive, is a third alternative. The grains in these flap discs are made to break apart and produce fresh, sharp edges. Ceramic flap discs last longer while maintaining their sharpness and cut rate. Ceramic flap discs are more expensive up front, but when other factors are taken into account, they frequently offer a lower overall cost of use. For grinding tougher materials like stainless, Inconel, titanium, armored, and tool steels, they are the ideal option.

MAINTENANCE PRACTICES TO INCREASE FLAP DISC LIFESPAN

Maximizing disc efficiency and lifetime requires proper technique. A flap disc may prematurely wear down or develop gouging, undercutting, heat buildup, and color fading if excessive pressure is applied. A disc that has coarse grit or a different disc may be needed if you need to exert more force to get it to work.

An excessive amount of pressure might harm the workpiece and raise safety and health issues. To reduce the danger of stress-related injuries, let the disc handle the work. Use a tool that is strong enough to maintain its rotational speed when utilizing premium cutting grains, such as ceramic alumina. The ability of the grain to fracture and self-sharpen is decreased when the pressure is too much because a weak grinder can "bog down" under strain.

For best performance, flap discs are created such that the entire width of the flap is utilized. Because they are not utilizing the entire breadth of the cloth while grinding at an excessively steep angle, both the operator and the disc must work significantly harder. Due to the increased tension on the flap, this can also shorten the lifespan of the device. An operator will frequently toss away a disc when the flap's edge prematurely wears, wasting a significant amount of the disc's abrasive material and value. Users who utilize Type 27 (flat) discs and grind at greater angles are more likely to experience this.

The full width of the flap can frequently be employed throughout the grinding operation by simply switching to a Type 29 (conical) disc, maximizing efficiency and minimizing disc use. Avoiding excessive metal removal while finishing thin material is especially crucial because doing so could result in a weak spot. This can be avoided by choosing the least aggressive disc that can nevertheless do the task, especially when tight tolerances are necessary.

It is recommended to start with a higher grit - 60 or 80 - then proceed down as necessary if more aggression is needed, if there is a worry about removing too much material too rapidly, or if a certain finish is wanted. Flap discs are intended to be used until adhesive is visible through the flap. A disc will keep cutting when used properly until the adhesive is apparent. This advice can result in significant annual product cost savings.

Flap discs are disposable tools, but some procedures may be performed to increase their lifespan and usefulness. It's crucial to keep in mind that various alternatives and settings are created to increase productivity, decrease downtime, and offer higher cost savings. For advice tailored to your needs, speak with the distributor representative or manufacturer in your area.

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