Abrasive machining uses small grains called grit to scrape hard surfaces, allowing for polishing, cutting, and reshaping of materials. Bonded and loose abrasives are used for different applications, with abrasive waterjet machining using pressurized water as an alternative to solid grit. Different grades of abrasives allow for tailored use in precision work.
Abrasive machining is the process of using abrasives to scrape the surface of hard objects. The small grains, called grit, are used to remove materials in small increments. The process is used to polish surfaces, cut hard materials or reshape steel.
Grit is what makes abrasive machining work. By using the grain as an abrasive, the operator is able to penetrate materials too hard for conventional cutting tools. It works when sand contacts the surface with a high force. The individual sand particles gradually wear away the surface. The process eventually removes enough material to create a cut or smooth surface, which polishes the object.
The abrasive can be bonded or loose. Bonded abrasives are abrasives attached to a matrix. This allows for greater control and accuracy because the die moves predictably. Bonded abrasives are used for sanding, diamond wire cutting and sawing. The matrix can be made in different shapes depending on its intended function.
A common example is sandpaper. The abrasives are coated on paper that can be held by hand. By regulating the speed and pressure of the hand movement, the person can control the sanding force of the sandpaper.
Loose abrasives are ideal for large or hard to reach surfaces. Abrasive blasting is a method that uses loose abrasives. Uses high pressure to drive abrasives across a surface to smooth, roughen or remove the surface layer.
There are a multitude of uses for abrasive machining in various industries. An abrasive cutting machine, such as an abrasive wheel, allows the operator to shape and cut metal and stone. Internal cavities can be smoothed out using abrasive flow machining. Lapping creates a uniform surface useful for precision work.
Abrasive waterjet machining is different from ordinary abrasive machines because it does not use solid grit. The water is pressurized and expelled in a concentrated jet to direct the stream onto the target surface. By using water as an abrasive, operators circumvent the two usual disadvantages of a normal abrasive machine.
First, some solid abrasives are expensive. Silicon carbide and diamond used as industrial abrasives are expensive to both produce and purchase. Second, the friction generated by the abrasive causes high heat, which adds cooling costs to the process. The water acts as both a coolant and an abrasive, which saves the operator additional costs.
The use of different grades of abrasives is especially useful for abrasive machining. Different grades allow the operator to tailor the abrasive to its function. Abrasive machining is used in jobs where there is little room for error. The right grade of abrasive can sometimes be the factor in a job well done.
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