EP2127809B1 - Vorgeformtes Schleifelement - Google Patents

Vorgeformtes Schleifelement Download PDF

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Publication number
EP2127809B1
EP2127809B1 EP20090159801 EP09159801A EP2127809B1 EP 2127809 B1 EP2127809 B1 EP 2127809B1 EP 20090159801 EP20090159801 EP 20090159801 EP 09159801 A EP09159801 A EP 09159801A EP 2127809 B1 EP2127809 B1 EP 2127809B1
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EP
European Patent Office
Prior art keywords
abrasive
weight
proportion
preshaped
binder
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EP20090159801
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English (en)
French (fr)
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EP2127809A1 (de
Inventor
Paolo Redaelli
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Redaelli Paolo
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Individual
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B31/00—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor
    • B24B31/12—Accessories; Protective equipment or safety devices; Installations for exhaustion of dust or for sound absorption specially adapted for machines covered by group B24B31/00
    • B24B31/14—Abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls

Definitions

  • the present invention relates to a preshaped abrasive element for mass finishing of surfaces, tumbling, vibro-finishing, and similar applications.
  • preshaped abrasives available worldwide for mass finishing surfaces, tumbling, and vibro finishing, also referred to as finishing "media", has remained substantially unchanged for about half a century.
  • finishing media The families of preshaped abrasives or finishing media are divided into the following general categories:
  • Polyester binder plastics are almost all obtained by casting a polyester thermosetting resin premixed with the powder abrasives in suitable moulds, which can be of varied materials and types. For hot-setting the moulds are inserted into appropriate kilns, while for cold-setting it is sufficient to wait for a reaction time during which the resin catalyzes and solidifies automatically inside the mould. On average a polyester plastic has a density of about 1.7 to 1.8 Kg./dm 3 .
  • the most common preshaped polyester elements on the market exhibit medium to high abrasiveness and average relative consumption of about 12 to 14% over 24 hours.
  • Relative consumption refers to consumption measured using only abrasive media over a fixed time, generally 24 hours, using a known machine, a known starting quantity, constant parameters (vibration, water, temperature, etc.), such as to enable comparison of different types of media, scientifically, over time.
  • Ureic binder plastics are formed by casting the resin in approximately the same way as for polyester binder plastics. On average a ureic plastic exhibits a density of about 1.4 to 1.5 Kg./dm 3 . The most common preshaped ureic plastic elements on the market exhibit a medium to high abrasiveness and average relative consumption of about 20 to 25% over 24 hours.
  • Ureic plastics known as "aminoplastics" are available on the market and can last longer compared to normal ureic plastics, offering the possibility of reducing wear and consequently the release of formaldehyde in industrial effluent. Average relative consumption measured on medium to high abrasives was about 13 to 16% over 24 hours.
  • Ceramic abrasives are mostly obtained by extruding a humid ceramic mixture of clay and abrasive, which is then cut, dried, and subsequently fired. Uncommon forms exist, including pyramids and cones, formed by moulding the humid ceramic mixture. On average a ceramic abrasive has a density of about 2.1 to 2.3 Kg./dm 3 .
  • the most common preshaped ceramic abrasives on the market exhibit medium to high abrasiveness and average relative consumption of about 5 to 10% over 24 hours.
  • the qualitative assessment parameters for ceramic abrasive elements generally also include a chipping fraction. This parameter is a percentage of small fragments detached from the projecting corners of the preshaped elements measured (percentage weight) after new ceramic elements are used for the first time. New preshaped ceramic abrasive elements exhibit a tendency to produce small chips as a consequence of relatively high firing temperatures during production generating microcrystaline structures typical of hard, dry materials.
  • porcelain ceramic abrasives exhibit a density of about 2.6 to 2.8 Kg./dm 3 .
  • Versions referred to as "high density porcelain” also exist, of densities up to about 3.1 to 3.3 Kg./dm 3 , for special processes or for processing particularly heavy products.
  • the most common preshaped porcelain ceramic abrasives on the market are substantially polishing in effect and exhibit very low average relative consumption, sometimes irrelevant at about 0.5 to 1.5% over 24 hours.
  • the assessment parameters for the quality of porcelain ceramic abrasives like normal ceramic abrasives, also include chipping. Before porcelain abrasives can provide good quality polishing, pre-treatment is often required, referred to as “conditioning” or "running-in”.
  • finishing media exhibit a series of technical problems as detailed below.
  • Polyester plastic binders can create problems both in olfactory terms and in the production of foam inside the machine. Even when these problems are not significant, there is always a problem of a waterproofing effect on the filterpress screens used in a section of the market for the treatment of effluent water. Compared to the effluent produced using ceramic or ureic media, polyester plastic binder media waterproof and/or obstruct filterpress screens much more rapidly, increasing the required level of routine maintenance interventions. In the majority of plastic abrasive elements available on the market dimensional and sometimes geometric variations are possible, dependent on the type of mould used, the type of casting, and the machines used.
  • Ureic binder plastics present problems both in olfactory terms (resulting from the release of formaldehyde into the air during storage, especially during the hot season) and in terms of weight loss over time, resulting from the continuous transudation of the water content of the base resin, especially in hot climates. Even when these problems are not significant, it is possible that transport during very cold periods, or storage in the open during very cold winters, can result in cracking of the abrasive elements, resulting from the increased volume of the water molecules contained in the preshaped elements. The most significant problem of preshaped ureic abrasive elements is very high consumption and an excess of free formaldehyde in the effluent. Like polyester plastic elements, ureic elements sometimes exhibit dimensional and geometric variability.
  • Ceramic abrasives are affected by chipping which results in objective problems during operations of automatic loading and unloading using tipping elevators, buckets, and all the automations involved in cascade loading systems.
  • the dropping of heavy items into a tumbling machine tank can cause fragmentation and chipping.
  • Porcelain ceramics exhibit problems of chipping similar or even worse than ceramic abrasives.
  • Porcelain firing temperatures can reach values as high as 1300°C resulting in extremely rigid crystal structures characterized by easy angular fragmentation.
  • a further typical problem of porcelain elements is the need for running in or conditioning before a high standard polish can be attained, due to the firing process giving the porcelain a relatively rough finished surface porosity.
  • Document US 3,684,466 discloses an organic polymer bonded tumbling chip, consisting essentially of 20 to 80% by weight of a thermoset organic polymer selected from the group consisting of unsaturated polyester, epoxy, and phenol-aldhehyde; 5 to 30% by weight of a powder thermoplastic selected from the group consisting of polyethylene, polypropylene, polytetrafluoroethylene, and polyamide, said thermoplastic polymer being of such degree of fineness to pass through a 10 mesh screen, and 0 to 75% by weight of abrasive.
  • a thermoset organic polymer selected from the group consisting of unsaturated polyester, epoxy, and phenol-aldhehyde
  • a powder thermoplastic selected from the group consisting of polyethylene, polypropylene, polytetrafluoroethylene, and polyamide, said thermoplastic polymer being of such degree of fineness to pass through a 10 mesh screen, and 0 to 75% by weight of abrasive.
  • the same invention aims to combine unprecedented formulation flexibility with a production precision which is free of the defects of the media of known type and summarized above, and therefore a precision in tune with the increasingly refined qualitative demands of the future.
  • the invention is also in tune with manufacturing techniques of low environmental impact and significant reduction of emissions, combined with wide-ranging possibilities for the recycling of the materials.
  • the present invention provides a preshaped abrasive element for mass finishing of surfaces, tumbling, vibro finishing, and similar applications, comprising at least an abrasive or a mixture of abrasives dispersed in both a thermoplastic binder and a thermosetting binder, as per claim 1.
  • a preshaped abrasive element of the invention serving as a substitute for a polyester binder plastic or a ureic binder plastic, possibly comprising an abrasive or a mixture of abrasives, for example quartz of variably fine qualities, in a proportion of 40% of weight, dispersed in both a thermoplastic binder, for example polyethylene, in a proportion of 40% of weight, and a thermosetting binder, for example polyester, in a proportion of 5% of weight, and comprising a further component, for example barite, serving to confer the preshaped element a required density, in a proportion of 15% of weight.
  • a thermoplastic binder for example polyethylene
  • a thermosetting binder for example polyester
  • a second type of preshaped element of the invention serving as a substitute for a ceramic abrasive element of known type, comprises an abrasive or a mixture of abrasives, for example red-brown corundum and white corundum, in a proportion of 5 to 25% of weight, dispersed in a thermoplastic binder, for example polyethylene in a proportion of 45% of weight, a thermosetting binder, for example polyester, in a proportion of 10% of weight, and comprising a further component, for example barite, serving to confer the preshaped element a required density, in a proportion of 20% of weight.
  • abrasive or a mixture of abrasives for example red-brown corundum and white corundum
  • a thermoplastic binder for example polyethylene in a proportion of 45% of weight
  • a thermosetting binder for example polyester
  • a further component for example barite
  • a third type of preshaped element of the invention serving as a substitute for a porcelain element, comprises an abrasive or a mixture of abrasives, for example alumina, in a proportion of 55% of weight, dispersed in both a thermoplastic binder, for example polyethylene in a proportion of 35% of weight, and a thermosetting binder, for example polyester, in a proportion of 5% of weight, and comprising a further component, for example zircon, serving to afford the preshaped element a required density, in a proportion of 5% of weight.
  • abrasive or a mixture of abrasives for example alumina
  • a thermoplastic binder for example polyethylene in a proportion of 35% of weight
  • a thermosetting binder for example polyester
  • substitute refers to an abrasive element of the invention, exhibiting a special composition and properties such that it can replace a corresponding abrasive element of known type, providing significant and surprising advantages as described below in the text of the present description.
  • the principal manufacturing technique for the abrasive elements of the invention is casting, providing preshaped abrasive elements exhibiting excellent geometric and dimensional constancy, with minimal shrinkage and not comparable with abrasive elements of known type.
  • the alternative manufacturing technique for the abrasive elements of the invention is extrusion, but limited to a few types and carefully designed to ensure maximum precision.
  • the media of the invention can achieve the same results in qualitative terms when formulated at similar density and abrasiveness to polyester binder plastic elements of known type.
  • the new media of the invention are formulated for increased abrasiveness and higher density the same results can be achieved in reduced times.
  • the manufacture of the preshaped abrasive elements of the invention foresees drastically reduced environmental impact as regards atmospheric emissions and reduced energy consumption for each kilogram produced. Residual waste materials (sizes no longer suitable for the process) can be recycled as second use raw materials, in limited percentages, for the manufacture of the elements of the invention.
  • the media of the invention can achieve the same results in qualitative terms when formulated at similar density and abrasiveness to ureic binder plastic elements.
  • the new media of the invention are formulated for increased abrasiveness and higher density the same results can be achieved in shorter times.
  • the manufacturing process foresees a drastically reduced environmental impact as regards atmospheric emissions and reduced energy consumption for each kilogram produced.
  • Residual waste materials can be recycled as second-use raw materials, in limited percentages, for the manufacture of the new media elements.
  • the media of the invention can achieve the same results in qualitative terms when formulated at similar density and abrasiveness to ceramic abrasive elements.
  • the manufacturing process foresees a drastically reduced environmental impact as regards atmospheric emissions and reduced energy consumption for each kilogram produced.
  • Residual waste materials can be recycled as second use raw materials, in limited percentages, for the manufacture of new media elements.
  • the media of the invention can achieve the same advantages as porcelain ceramic abrasive elements, with the exclusion of the rate of consumption.
  • the new media does not exhibit lower consumption rates than a porcelain ceramic media.
  • the surface of the preshaped element of the invention is already smooth and does not require runnin-in before use for polishing.
  • the typical formulation of the media of the invention comprises at least the following characteristic components:
  • the first two components together comprise an innovative form of binder. Though known separately, the combination of the two binders has proved innovative, in particular after conceiving the idea of generating a series of extremely multi-purpose media. Technical process testing based on formulations comprising variable proportions of the two binders have led to important improvements in the results. - An abrasive or mixture of abrasives.
  • the series of media of the invention can be manufactured using a very heterogeneous variety of abrasives including quartz (typically combined with the plastic and ureic media of known type), corundum (typically combined with ceramic media of known type), aluminium oxides, neosilicates, tectosilicates, providing variants of hardness, granulometry, and crystalline structure capable of exercising the most varied actions from general stripping to micro polishing.
  • the abrasives characterizing each individual formulation of the new media can be of a single type or blends of multiple types such as to provide a balancing of finishing action on the basis of design requirements.
  • An important intrinsic characteristic of the media of the invention is the possibility of simulating an action of a preshaped abrasive media of known type. To achieve this it is essential to formulate a density more typical of ceramics than of plastic, as described below.
  • an ideal formulation might be based on binders and abrasives resulting in a density of 1.85 Kg/dm 3
  • the formulation of the invention can also emulate a density required by a process, which for example could be 2.9 Kg/dm 3 .
  • a media of density 2.9 Kg/dm 3 behaves very differently from media of density 1.85 Kg/dm 3 , but not only.
  • a tumbling machine for example of vibrating, circular tank type, can behave differently both as regards vibratory motion (spiral dynamics arising from a combination of rotary motion and translation), and as regards amplitude (millimetres of displacement between the upper and lower limits of a sussultatory motion of a vibrating tank).
  • the loading capacity of tanks is generally expressed in litres. If a 1000 litre volume tank is loaded with abrasives of 1.85 Kg/dm 3 the load is 1850 Kg. If the same volume is loaded with abrasives of 2.85 Kg/dm 3 the load is 2850 Kg., the difference in load being 1000 Kg. and proportionally 54% greater. Consequently, a machine requires at least adjustment of its vibrational motion (angular and/or eccentric adjustment, centrifugal force) in order to determine the necessary forces intended, for example, for correct automatic extraction or, simply, to achieve the ideal values of amplitude and operational dynamics.
  • weight plays an important role in accelerating an abrasive action. For example, a hand lightly running sandpaper over a surface does not achieve the same effect as a hand pressing down hard. Weight is also important in cases in which very heavy metal items are inserted into the abrasive mass loaded in a machine for fine finishing treatment. Clearly when using a relatively low mass media a lack of the necessary “insulation” and “shock - absorbence” can develop between the items, which can approach each other, inadequately cushioned, at excessive speed, resulting in impact shocks and surface damage. Having established the importance of an appropriate media density, it is clear that the new media provide an important development in this respect as a result of the balancing of the formula with a component that enables adjustment of density as required, representing a sort of "density modulator".

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Claims (4)

  1. Ein vorgeformtes Schleifelement zur Oberflächenveredlung, Gleitschleifen, Vibrationsschleifen und ähnliche Anwendungen, umfassend mindestens eine Schleifkomponente oder eine Mischung von Schleifkomponenten, verteilt in sowohl einem thermoplastischen Bindemittel als auch einem wärmehärtendem Bindemittel, wobei das vorgeformte Schleifelement die Schleifkomponente oder eine Mischung von Schleifkomponenten in einem Anteil von 25 Gew.-% bis 55 Gew.-% umfasst, verteilt in sowohl dem thermoplastischen Bindemittel in einem Anteil von 35 Gew.-% bis 55 Gew.-% als auch in dem wärmehärtendem Bindemittel in einem Anteil von 5 Gew.-% bis 10 Gew.-% wobei das vorgeformte Schleifelement zudem eine weitere Komponente umfasst, die aus der Gruppe, bestehend aus Baryt, Siliziumcarbid, Feldspat, Glashohlkugeln und Zirkon ausgewählt ist, wobei die zusätzliche Komponente dazu dient, dem vorgeformten Element eine benötigte Dichte zu verleihen, in einem Anteil von 5 Gew.-% bis 20 Gew.-%.
  2. Das vorgeformte Schleifelement gemäß Anspruch 1, wobei dieses als ein Ersatzmittel für ein Polyester-Kunststoffbindemittel oder ein Harnstoff-Kunststoffbindemittel dient, dadurch gekennzeichnet, dass dieses eine Schleifkomponente oder eine Mischung von Schleifkomponenten in einem Anteil von 40 Gew.-% umfasst, verteilt in sowohl einem thermoplastischen Bindemittel in einem Anteil von 40 Gew.-% als auch einem wärmehärtenden Bindemittel in einem Anteil von 5 Gew.-%, und eine zusätzliche Komponente umfasst, die dem vorgeformten Element eine benötigte Dichte verleiht, in einem Anteil von 15 Gew.-%.
  3. Das vorgeformte Schleifelement gemäß Anspruch 1, wobei dieses als ein Ersatzmittel für ein keramisches Schleifelement einer bekannten Art dient, dadurch gekennzeichnet, dass dieses eine Schleifkomponente oder eine Mischung von Schleifkomponenten in einem Anteil von 25 Gew.-% umfasst, verteilt in sowohl einem thermoplastischen Bindemittel in einem Anteil von 45 Gew.-% als auch einem wärmehärtendem Bindemittel in einem Anteil von 10 Gew.-%, und eine zusätzliche Komponente umfasst, die dem vorgeformten Element eine benötigte Dichte verleiht, in einem Anteil von 20 Gew.-%.
  4. Das vorgeformte Schleifelement gemäß Anspruch 1, wobei dieses als ein Ersatzmittel für ein Porzellan-Keramik-Element dient, dadurch gekennzeichnet, dass dieses eine Schleifkomponente oder eine Mischung von Schleifkomponenten in einem Anteil von 55 Gew.-% umfasst, verteilt in sowohl einem thermoplastischen Bindemittel in einem Anteil von 35 Gew.-% als auch einem wärmehärtendem Bindemittel in einem Anteil von 5 Gew.-%, und eine zusätzliche Komponente umfasst, die dem vorgeformten Element eine benötigte Dichte verleiht, in einem Anteil von 5 Gew.-%.
EP20090159801 2008-05-26 2009-05-08 Vorgeformtes Schleifelement Active EP2127809B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
ITMI20080973 ITMI20080973A1 (it) 2008-05-26 2008-05-26 '' elemento preformato abrasivo ''

Publications (2)

Publication Number Publication Date
EP2127809A1 EP2127809A1 (de) 2009-12-02
EP2127809B1 true EP2127809B1 (de) 2014-12-03

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IT (1) ITMI20080973A1 (de)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT1400482B1 (it) * 2010-05-27 2013-06-11 Redaelli Processo ad umido di finitura in massa di superfici
IT201900007052A1 (it) 2019-05-21 2020-11-21 Paolo Redaelli Metodo per vibrosabbiatura perfezionato e macchina relativa
DE102021101995A1 (de) * 2021-01-28 2022-07-28 Dyemansion Gmbh Kunststoffstrahlmittel sowie Verwendung eines Kunststoffstrahlmittels

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3684466A (en) * 1971-01-28 1972-08-15 Joseph V Petrone Organic polymer bonded tumbling chip

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ITMI20080973A1 (it) 2009-11-27
EP2127809A1 (de) 2009-12-02

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