RollRoll Grinding,Grinding, Superfinishing Superfinishing andand MicrofinishingMicrofinishing SystemsSystems

Our technology can In our fast-paced world, everybody wants to capture more of the market. And that means help you finish first. producing products that perform better, last longer and cost less. Which is why 3M technology is ideal for the 90's and beyond. 3M film-backed and flexible produce consistently uniform finishes faster and more efficiently than other traditional roll grinding and cylindrical finishers. Once you take a close look at our unique abrasives, you'll see why they are better suited for finishing cylindrical parts like crankshafts and camshafts and for grinding rolls. The best reasons for For years, grinding wheels and bonded stones, abrasive sheets—even slurries— using 3M are the have constituted the usual means for resurfacing, dimensioning and polishing rolls and oldest reasons. cylindrical parts. These traditional methods of roll finishing are typically slow and leave room for operator error. Fortunately, 3M film-backed and flexible diamond abrasives offer fast, easy-to-use predictable alternatives.

More cost-effective 3M film-backed and flexible diamond abrasives provide predictable, consistent and repeatable ways to obtain uniform performances every time for your roll finishing operations. These film-backed and flexible roll finishes with 3M. diamond abrasives enable you to quickly remove traverse marks and feed lines, eliminate chatter, follow existing geometry (including crowns) and consistently obtain sub-1 micro inch Ra (.025 microns) or finer finishes on chrome, compressed paper, nylon, chilled iron, rotogravure, epoxy and polyurethane rolls and other non-roll surfaces.

Controlled pressures, belt tension and workpiece rotational speeds result in consistent stock The combination of continuously fed 3M film-backed abrasives and the rotation of the removal and dimensional accuracy to prepare a uniform surface for further polishing. workpiece give you the capability to create uniform, consistently even finishes down to sub-1 micro inch Ra.

Roll Grinding Superfinishing Roll grinding is typically the first step in the system. 3M™ Superfinishing is an extremely versatile way to produce Flexible Diamond belts are introduced to a rotating cylindrical predictable, repeatable finishes on rolls used for a variety of workpiece. The flexible diamond abrasive quickly dimensions industrial tasks. The ability to generate consistently uniform parts by removing lobes and leaving the workpiece surface finishes enables operators to extend roll life by eliminating ready for further superfinishing. Flexible diamond abrasive the damage caused by traditional roll grinding methods. belts enable you to match tighter tolerances for diameter, Superfinishing with 3M film-backed abrasives also allows roundness, profile flatness and bearing ratio. operators to choose a variety of surface textures from linear scratch to cross-hatching.

Oscillating abrasive across an existing straight line scratch rapidly reduces the existing peaks and valleys. Different oscillation frequencies create different scratch patterns and allows the operator to see when previous scratches have been removed and the finishing step is completed. Compared to conventional cloth and paper backings, film is a far more consistent substrate for the precise application of resins and micron-graded mineral. Film backings hold abrasive particles on top of the substrate, do not compress or lose particles in the backing.

Film F weight paper J weight cotton cloth

Microfinishing enables you to correct geometry and obtain fine Centerless microfinishing plunges the workpiece into the abrasive to finishes (as low as 1 to 2 micro inches or 0.025 to 0.05 µm Ra). remove stock or provide a polished finish.

Microfinishing Centerless Microfinishing Usually, a microfinishing process employs rigid shoes instead Centerless Microfinishing is ideal for cylindrical parts that of a contact roller or platen to support the abrasive film. The are not effectively processed in lathes or between centers. workpiece, such as a crankshaft or camshaft, is turned and The process utilizes the consistent, uniform film backing and oscillated between centers as shoes introduce the abrasive to micron graded minerals of 3M microfinishing abrasives to the work interface. Fresh abrasive is incrementally indexed eliminate lead lines and traverse patterns while letting you after each part is processed, resulting in uniform stock control cycle time, oscillation frequency, abrasive advance removal and finish, part after part. Microfinishing removes and workpiece rotational speeds. Rolls of abrasive are easily the damaged or amorphous layers to improve the surface changed in minutes to produce sequentially finer finishes. finish and roundness of the part and, in many cases, can eliminate the need for an entire grinding operation. If you want a super Compared to conventional cloth and paper backings, film backings provide a superior, uniform finish, start with 3MTM surface to coat with micron graded minerals. The uniform application of abrasive mineral with Superabrasives and a unique resin bond creates the ability to provide a more consistent, repeatable finish. Microfinishing films.

Notation: 3M™ Microfinishing Film is shown abrasive side up, product reads correctly from the back side.

3M™ Flexible Diamond Belts 3M™ Microfinishing Film 3M™ Flexible Diamond Belts allow you to achieve better 3M™ Microfinishing Film is a fast cutting finishes without sacrificing cut rates on hard to grind roll abrasive that can produce consistent, predictable and materials. A metal bond securely anchors micron graded repeatable high quality finishes on roll surfaces. This to our premium, flexible backing. It offers abrasive utilizes precision micron graded mineral particles durability and longer life while allowing conformance to a that are electrostatically oriented, then resin-bonded to a variety of contours. The open dot pattern produces aggressive polyester film backing to give an aggressive cut with a cutting action and reduces grinding loads. Especially uniform finish. Available in 9-100 micron grades. designed for use on rolls harder than 55-60 Rockwell C such as chilled iron, forged steel, thermal sprays or . P grading vs. Conventionally graded micron grading chart abrasives on cloth backing

Micron graded abrasives on film backing

3M™ Film 3M™ Diamond Lapping Film 3M™ Lapping Film is a premium, precision 3M™ Diamond Lapping Film offers a repeatable, precision abrasive that produces super-fine, super-consistent Ra finishes finish on a variety of hard materials such as tungsten car- on rolls made of a variety of metals, plastics and rubber. A bide, thermal or plasma sprayed ceramics, (chrome oxide and high strength polyester backing provides a uniform base for a aluminum oxide) glass, stone and some hardened, high car- coating of micron graded mineral particles. A carefully bon ferrous metals. It combines micron graded diamond par- controlled resin bond ensures a consistent, predictable and ticles, a tough resin bonding system and a highly uniform repeatable finish. Available in 0.3-60 micron grades. polyester film backing to produce high quality finishes, consistently, predictably and economically on harder roll surfaces. Available in 0.1-45 micron grades. 3M film-backed and All 3M film-backed and flexible diamond abrasives provide a predictable, consistent and flexible diamond repeatable finish for all types of industries, including: steel mills, aluminum mills, film abrasives for tough extruders, decorative stainless, paper mills, textiles, printing industry, copper foil electro- markets. deposition and other non-roll applications. 3M film-backed and flexible diamond abrasives are ideal for roll finishing on tungsten carbide, chilled iron, forged steel, chrome plating, stainless steel, rubber, nylon, copper, brass, tool steel, aluminum, epoxy, thermal spray ceramics, tungsten carbide, nickel, polyurethane, ceramics and more.

crankshaft

diesel wrist pin

engine valve plungers stems wrist pin fuel injection components

automotive camshaft hydraulic cylinder

fuel injection components

polished roll

transmission yoke

tapered roller bearing races

shock absorber rod Roll Grinding and Superfinishing with Superabrasives 3M’s Technical Service Engineers recommend using the following sequences for roll grinding and superfinishing a variety of roll materials. Your actual process and surface finishes may vary depending on your performance requirements and process equipment.

Roll Grinding Sequential Surface Finishes Obtained (Ra micro inch)

Roll 3M Flexible Diamond Grade Material M250u M125u M74u M40u M20u M10u

Thermal Spray Coatings: Ra 90 40-50 27-30 11-14 6-8 3-4 Tungsten Carbide Chrome Oxide Rmax 723 462 267 179 118 40 Aluminum Oxide Amps over Idle 4-8 4-8 4-6 2-4 2 1-2

Chilled Iron Ra — 38 28 16-20 8-10 2-6 Forged Steel Rmax — 390 262 162-198 84-102 22-68

Amps over Idle — 4-8 4-8 4-6 2-4 2

Operating Conditions

Belt Speed 7000-9000 sfpm Abrasive Feed Direction Opposing workpiece rotation Work Piece Speed 100-300 sfpm Dwell/Traverse Rate 50% overlap Contact Wheel 90A plane face Coolant Water with rust inhibitor

Superfinishing Sequential Surface Finishes Obtained (Ra micro inch)

3MTM Diamond Lapping Film - Micron Grade Roll Material 30u 15u 9u 3u

Thermal Spray Coatings: 2 Ra 1-2 1 <1 Tungsten Carbide (two passes required) Chrome Oxide Aluminum Oxide Rmax 49 39 25 15

Chilled Iron 4 Ra 3 2 1 Forged Steel (two passes required)

Rmax 42 33 21 9

Operating Conditions

Abrasive Speed 1 inch/minute Pressure 50-350 PSI Workpiece Speed 100-4 sfpm Traverse Rate 6 inches/minute Roll/Platen 63A Coolant Water with rust inhibitor Oscillation Alternating full-low Superfinishing with 3M™ Microfinishing Film and 3M™ Lapping Film

Superfinishing Sequential Surface Finishes Obtained (Ra micro inch)

Roll Max. MFF MFF MFF MFF LF LF LF LF PF Material Starting 3M 272L 3M 272L 3M 272L 3M 272L OR 3M 261X 3M 261X 3M 261X 3M 261X 3M 971X Finish 60µ 30µ 15µ 9µ 30µ 12µ 9µ 3µ 1µ

Chrome <20 12-14 5-6 2-3 1.5-2 1 <1 <1 <1

6061 Aluminum <90 60 35-38 26-28 11-13 5 3 1-2

Brass <90 80 31-34 11 4-5 2 1 <1

304 Stainless Steel <30 22-24 8-9 4-5 2-3 1-2 <1 <1

DR02 Tool Steel 42 RC <40 20 9-10 3-4 2-3 1-2 <1 <1

1018 Steel <40 20-24 9-11 3-4 2-3 1-2 <1 <1

Nylon 90A <80 60-65 20-25 11-13 6-7 3 2 1

MFF MFF MFF MFF LF LF LF LF 3M 472L 3M 472L 3M 472L 3M 472L OR 3M 461X 3M 461X 3M 461X 3M 461X 60µ 30µ 15µ 9µ 30µ 15µ 9µ 5µ

Rubber 58D 100A 200 60-62 20-23 11-12 7-8 4-5 2 1-2

Operating Conditions Key

Abrasive Speed 1-2 inches/minute MFF 3MTM Microfinishing Film Pressure 40-50 lbs. for MFF steps LF 3MTM Lapping Film 20-40 lbs. for LF steps PF 3MTM Polishing Film Work Piece Speed 100-300 sfpm Dwell/Traverse Rate 50% overlap Roll Platen 60A for MFF 40A for LF Oscillation Alternating full-low Coolant Water with rust inhibitor For more information: For more information on roll grinding, superfinishing, microfinishing and centerless microfinishing, or for help determining your stock removal needs, part size and cycle time requirements, contact your authorized 3M distributor or write: Superabrasives and Microfinishing Systems Division 3M Center, Bldg. 251-2E-04 St. Paul, MN 55144-1000. Or call: 1-800-742-9546. In Minnesota call: (651) 737-1783.

Superabrasives and Microfinishing Systems Division 3M Center, Building 251-2E-04 St. Paul, MN 55144-1000 Recycled paper Litho in USA with 3M films, proofing 651 737 1783 Telephone 50% pre-consumer systems and offset plates. 800 742 9546 Toll-free 10% post-consumer © 3M 1996 60-4400-4238-4(711)JR