Flexovit Abrasives Training

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flexovitabrasives.com

Flexovit Overview

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Topics

1. Introduction to Flexovit

2. Abrasives Overview, with Focus on Reinforced Resin Bonded

3. Introduction to Flexovit Product Tiers

4. Grinding and Cutoff Wheel Safety

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Corporate Offices & Manufacturing Facility

Located in
Angola, New York

• 100,000 Square
Foot manufacturing

facility.

• Most technologically-advanced grinding wheel manufacturer
in North America.

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Manufacturing Facility

• Flexovit manufactures the entire
bonded abrasive wheel including the
die-cast spin-on hubs, and
fiberglass reinforcements.

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Product Testing
Completed at our factory...

• ISO 9001:2008 Certified

• On-Site Testing Lab

• On-Site R&D Lab

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Topics

1. Introduction to Flexovit

2. Abrasives Overview- with Focus on Reinforced Resin Bonded

3. Introduction to Flexovit Product Tiers

4. Grinding and Cutoff Wheel Safety

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Abrasives Overview
- with Focus on Reinforced Resin Bonded
The four main abrasive systems are:
Bonded Coated
Abrasives Abrasives

Non Woven Superabrasives
Abrasives

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Bonded Abrasive Wheels

Resin Bond
The resin bond is tough and resilient.
Resin bond wheels may also be
reinforced with fiberglass mesh
for added strength.
Because of their strength
they are recommended
for thin cutoff wheels, and
for grinding wheels that are
subjected to severe lateral
pressure or shock, including
wheels used on portable power tools.

Vitrified Bond Rubber Bond
Is a rigid bond, somewhat fragile, used Composed of synthetic or natural rubber. It is used
primarily for precision grinding and finishing extensively on thin cutoff wheels for burr-free cuts,
operations. It is not recommended for surface as well as regulating wheels on centerless
speeds over 6,500 feet per minute. Vitrified grinders. These wheels are relatively fragile, and
wheels are typically used on stationary therefore used on stationary machines with a fixed
machines. cutting plane and securely clamped workpiece.

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Resin Bonded Abrasive Wheels
- How a Grinding Wheel is Made: Components

Abrasive Resin Fiberglass
Grains Bonds Reinforcing

Arbor Wheel
Spin-on
Ring Label
Hub

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- How a Grinding Wheel is Made: Grains
The four main types of abrasive grains used in Resin Bonded wheels are:
Aluminum Silicon
Oxide Zirconia
Carbide
Alumina
Ceramic

• Tough, blocky, wedge shaped
• Extremely hard and
grain. sharp, but fractures more • Very tough, sharp, and
dense. • Sharp microcrystalline
easily than aluminum
grain-cuts aggressively
oxide.
• Lends itself to higher under light to moderate
• Performs well on carbon steel,
temperatures and pressure.
• Performs well on Cast
stainless steel and aluminum. heavier pressures
Iron, Nonferrous Metals
present in high-stock • Its quick cutting
(Aluminum) and Non-
removal applications capability makes it
Metallic materials including
suitable for grinding
Concrete, brick, marble and
stainless steel, titanium,
glass.
and high-nickel alloys.

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- How a Grinding Wheel is Made: Grains
Determining Grit Size:
Abrasive grains are sized by passing them over screens having a certain number of openings per linear
inch. The number of openings per linear inch in the screen through which the particles just pass
determines the grit size. Resin bonded wheels typically use relatively coarse grits such as 24 and 36.

Coarse Grit Size (30 Grit) Fine Grit Size (108 Grit)

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- How a Grinding Wheel is Made: Fiberglass Reinforcing
High tensile fiberglass mesh is incorporated in the wheel for more durability.

Grinding Matrix
Backing Matrix

7 x 1/4 x 5/8-11 Triple-Layered fiberglass-Reinforced,
Depressed-Center Grinding Wheel, Product Code A5356H

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- Understanding the Specification (Spec)
ex. A30S
1.) Abrasive Grain 2.) Grit Size 3.) Grade/Hardness*

A 30 S
A = Aluminum Oxide 16 Coarse M Soft

C = Silicon Carbide 30 Medium R Harder
S
ZA = Zirconia Alumina 60 Fine T Harder

CG = Ceramic 120 Very Fine Z Hardest

*Each grain of abrasives is joined to other grains by a bond material. The strength with which this bond hold the grains is
known as the grade or 'hardness' of the wheel. Grade or hardness is expressed by a letter of the alphabet, with 'A' being the
softest and 'Z' indicating the hardest bond.

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- How a Grinding Wheel Works

The Cutting Tool Principle:

Abrasive • Abrasive grain begins to • Other abrasive grains • Before the edges of the
Wheel Grains Workpiece cut chips from the are revealed as the wheel abrasive grain become
workpiece’s surface. As it bond wears from contact too dull, they are torn
Bond does, the grain begins to with the workpiece. away from the wheel
wear down. It fractures, bond, allowing other
presenting a new sharp abrasive grains to come
edge. into play.

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- Wheel Construction: Hardbak
Flexovit’s Hardbak wheel design boosts productivity and safety on the shop floor by eliminating premature
shedding and shearing of grain from the leading edge of the grinding face.

The Hardbak design incorporates
a thin layer of relatively fine abrasive
grain and hard bond sandwiched
between two full diameters of
fiberglass. The remainder of the
wheel is comprised of two thick
layers of coarse grit and bond.
These are separated by a third full
diameter of fiberglass reinforcing.
The leading edge of the grinding face
is now resistant to grain shedding or
chipping, allowing the coarser grain to
fully do its work and eliminate the Flexovit
Wheel Competitor Wheel
hazard of flying chunks of abrasive.
with Hardbak without Hardbak

Hardbak is incorporated in the design of all Flexovit 7” and 9” depressed center grinding wheels as well as in
all premium (Flexon) and semi-premium (Metalhog) depressed center grinding wheels.

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Wheel Types - Reinforced
Type 27: Depressed-Center Wheels
Grinding wheels are designed to be used at a 30 degree angle from
the workpiece. Cutoff wheels are designed to be used at a 90 degree
angle to the workpiece and may be used for flush cutting.

Type 28: Saucer Shaped Wheels
This wheel operates at a wider contact area than the Type 27, resulting
sometimes in a better finish, but it also offers more aggressive stock
removal. It can be used at shallower angles, 10 to 15 degrees
from workpiece.

Type 29: Flared Up
(Found in Zircotex/ZircoMax Flap Discs & Flexcel Wheels)
Fiberglass reinforced depressed center product, featuring a flared
profile with a convex surface on one side. This shape allows a wide
contact area, and can be used at a greater variety of angles,
anywhere from 10 to 30 degrees.

Type 1: Flat
A round, flat wheel with a hole in the middle. These wheels are designed
for grinding or cutting on the periphery, or edge, of the wheel only.
They may or may not be fiberglass reinforced.

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Wheel Types - Non Reinforced

Type 1: Flat - Bench Grinder Wheels
A round, flat wheel with a hole in the middle. These wheels are designed
for grinding or cutting on the periphery, or edge, of the wheel only.

Type 11: Flaring Cup Wheels
- Also called: ‘Cup Rocks’ or ‘Cupstones’
Resin bonded cup wheels are used for heavy stock removal applications. Unlike
depressed center wheels, these wheels are not fiberglass reinforced.

Type 16,17 Plugs & Cones
18 & 18R: These are designed for difficult to reach places, such as odd-shaped castings. Good
for internal grinding as well.

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Flexovit Product Tiers Product Offerings
Depressed Center Wheels, Cup Wheels, Plugs & Cones, Bench Grinder Wheels,
Mounted Points, Die Grinder Wheels, Cutoff Wheels, Coated Abrasive Products, Non-
Woven Abrasive Products, Carbide Burs, & Wire Brushes.

Depressed Center Wheels, Circular Saw Wheels, & Stationary Saw Wheels

Depressed Center Grinding, Cutoff and Combination Wheels, Cup Wheels, Die Grinder
Wheels, Cutoff Wheels & Resin Fiber Sanding Discs.

Depressed Center Wheels, Cutoff Wheels, Resin Fiber Sanding Discs

Thin Cutoff Wheels & Depressed Center Thin Cutoff Wheels

Semi-Flexible Grinding / Blending / Finishing Discs

Super Flap Discs High Density Super Flap Discs

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Flexovit Product Tiers Descriptions

The wheels are the hardest working aluminum oxide wheels available. Precision made to ensure smooth
and safe operation, these versatile products set the standard for fast material removal, and rugged
reliability and long life.

Metalhog wheels incorporate a blend of premium, semi-premium, and standard abrasive grains with
custom bond systems. This produces an extremely aggressive wheel, without sacrificing wheel life.

Offering a combination of premium Zirconia and Ceramic grains with advanced bond systems, these
wheels deliver the highest productivity.

Specially designed to optimize performance on a particular material. Flexovit Specialist wheels are
available for a variety of materials including; stainless steel, aluminum and concrete/masonry.

Flexovit’s Razorblade series of thin cutoff wheels for angle grinders are an indispensable tool for the
metalworker in both production and maintenance applications. Choose from 5 versatile specs depending
on the job requirement. Available in Type 1 as well as Type 27.

These semi-flexible wheels remove material like depressed center wheel, yet blend and finish like a resin
fiber disc. Flexs to contoured surfaces delivering a smooth finish without gouging.

Extremely productive & efficient. Delivers twice the removal rate as our
Ideal for high production grinding, conventional Zircotex discs. Provides
blending , deburring and finishing, it extremely long life and is our most producti
performs well on a variety of flap disc.
materials.

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Who’s responsibility is safety?

Machine Builder Wheel Manufacturer

User

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Machine Builder
The machine builder must make certain at the time of manufacture that the
machine is of suitable design and properly guarded for the operation.

Machine must be adequately guarded. Wheels can only be used on
machines with safety guards that meet A.N.S.I. and O.S.H.A. specifications.
Generally, a safety guard should enclose one-half of the wheel.

MACHINE MUST HAVE PROPER FLANGES. Wheels can only be used
between flanges mounted in accordance with A.N.S.I. specifications. Generally,
flanges should be at least one-third the diameter of the wheel. Flanges should be
kept in good repair and must be checked periodically for flatness, burrs or wear.

MACHINE SHOULD BE WELL MAINTAINED. Wheels can only be used on
machines regularly maintained by qualified personnel including periodic check of
free running spindle speed (RPM).

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Wheel Manufacturer
The wheel manufacturer must make certain that the wheels are manufactured to meet or
exceed specification and have been tested in accordance with the ANSI standard B7.1- 2000
safety requirements for the use care and protection of abrasive wheels and are marked with
the maximum operating speed as well as all necessary safety information.

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Features of a
Flexovit Wheel
Label

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Wheel Manufacturer

As we covered earlier, grinding wheels are made of thousands of small abrasive grains
that have been bonded together using an organic resin compound. The bond must be
strong enough to hold the abrasive grains in place, yet friable enough to release dull
grain and expose fresh cutting points. (Friable refers to the property that makes the abrasive
capable of breaking down during the grinding process.) An unbreakable wheel simply would not grind.

Fiberglass reinforcements of varying sizes and mesh,
are used to strengthen the wheel. The material must
first be coated with a resin to facilitate proper bonding
to the abrasive matrix.

The resin holds the wheel together. Poor quality
resins can cause quick wear or wheel
Fiberglass
disintegration.
Reinforcing

Abrasive
Resin Grains
Bonds

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User

The user is responsible for the proper handling,
storage and inspection of grinding wheels after
receiving the product.

The user must maintain the equipment in safe
operating condition at all times. This includes
periodic speed checks of the equipment.

All operating personnel must be instructed in the
safe use of their particular equipment. It is
imperative they use the proper wheel for the
machine and they must be sure the maximum
rated machine speed DOES NOT exceed that of
the wheel.

Protection of operating personnel, as well as
those in adjacent areas, must be maintained at all
times. It is the users responsibility to use and
maintain guards and other protective devices.

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User - Handling and Storage

Suitable racks, bins drawers, pins or boxes shall be provided to store the various types of wheels.
Depressed center wheels -should be stored flat or hung on pins.

Cutoff wheels -should be stored flat. Do not stand them on their edge
as they are subject to warping.

Bench and pedestal wheels -should be stored flat or standing on their
edge and each should be stored in a protective corrugated sleeve.
Wheels should NOT be stored/subject to (causes of bond degradation):
a) Water or other solvents
b) Any temperature or humidity condition that causes condensation on If a grinding wheel has been or is
the wheels suspected of having been damaged,
c) Freezing temperatures- special attention should be taken for wheels DO NOT USE IT.
stored in mobile storage areas.

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User - Machine

USE PROPER FLANGES
Both flanges, of any type, between which a wheel is mounted, should be of the same diameter and have
equal bearing surfaces. Depressed center wheels, over 7” in diameter, should have a CP50 adapter.
Check all flanges for wear and deflection.

DO NOT OVER TIGHTEN
Please tighten the wheel snugly! Over tightening causes several problems. It can bend the flanges by
crushing them. It can also set up dangerous stresses in the wheel, which when centrifugal force is
introduced, can cause the wheel to fail.

USE CORRECT MACHINE FOR WHEEL
Always make sure you have the proper machine for the wheel you are using. DO NOT USE A
DEPRESSED CENTER WHEEL ON A PISTOL GRIP SANDER. Always check wheel speeds before
mounting!

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User - Mounting

INSPECT WHEELS
Visually inspect all wheels before mounting. Also inspect the packaging. If the wheel or packaging show
any evidence of abuse, please do not mount them. Defects such as broken wheels, chips and gouges can
be detected visually. Cracks in abrasive wheels are frequently not visible to the naked eye.

To test for cracks in a vitrified wheel (bench or pedestal), administer a ring test.

For organic bonded wheels (depressed center or cutoff), use proper start up procedures. (see ANSI 9.8 pg 111)

CHECK SPEEDS
Always compare maximum wheel and machine speed. The machine speed must be the lesser of the two.

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User - Mounting

USE PROPER GUARDS
Please use a guard! If breakage of abrasive wheels could be
prevented, there would be no need for a guard. Conversely, if all
machines could be completely guarded there would be no cause for
worry about wheel breakage. However, both must be considered.
Everything must be done to prevent wheel breakage and proper guards
must be used. When using a grinding or cutting wheel ensure that the
machine guard is positioned between the wheel and the operator.

CHECK MACHINE SPEED
Air tools should be checked every 20 hours or once per week. Electric
tools should be tested monthly. All tools should be tested after repair
or maintenance.

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User - Use and Operation

SAFETY WEAR
Proper eye and body protection not only makes good
sense, it is the law in parts of our country. Glasses,
gloves, goggles, shields and ear protection….
Whatever you can practically handle. Keep in mind,
The peripheral speed of a 7” grinding wheel equals
That of a .38 caliber bullet. Even a small piece of debris
Is extremely dangerous.

START UP
When starting any grinding wheel, whether new or used, stay away from it! If it is a portable
application, start the wheel with the rotation turning away from you or in a protected area. If it is a
stationary application, stand off to on side when you start up.

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Use and Operation - Proper Use

All wheels have a particular application.
Please use the wheel for what it was designed.

Grinding Notching

Smoothing

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Use and Operation - Common Misuses

Deburring or beveling on the side of a type 1 cutoff wheel.
This will sheer reinforcing that will cause premature failure
when the wheel is subject to heavy cutting.

Too shallow a grinding angle with type 27
depressed center wheels causing an undermining
of the reinforcing. This sets up for wheel failure
when aggressive grinding pressure is introduced
onto the wheel.

Improperly tightened flanges on a large diameter cutoff wheel. Loose
flanges spin against the wheel rather than supporting the wheel.
This results in the arbor of the wheel failing.

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Observe These Safety Tips:

1. Check all wheels for cracks or damage before use.

2. Run the wheel in a protected area for one minute before grinding.

3. Don't use wheels that have been dropped or otherwise damaged.

4. Don't apply side pressure on any Type 1 straight wheel or Type 27 thin wheel.

5. Don't use a grinding wheel with a rated speed less than that of the grinder.

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For Complete Safety Information
please refer to the
American National Standards Book
ANSI B7.1-2000

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We Hope You Found This Presentation
Informative.

Thank You for Your Time.

Flexovit Abrasives Training

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