Enhance performance by choosing the correct abrasives

September 2018 - Abrasive technology has evolved drastically over the past 25 years, which has raised the bar for the types of products that meet quality standards at large manufacturing facilities. Although a particular abrasive often will work in a given application, it may not be the best product for the job at hand. A classic example is a customer using an aluminum oxide resin fiber disc to grind welds on stainless steel. The aluminum oxide will work to a certain degree, but performance will be dramatically enhanced by using a zirconia or ceramic disc, which is better suited for stainless steel applications.

Sales personnel can help guide customers through the abrasive evaluation process. End users often will test sanding discs by having an employee grind for 30 seconds with each disc and then make a decision based on which one he likes best. Ideally, though, the process should be more systematic by evaluating product price, stock removal rate and labor rate.

The cost per unit of an abrasive product alone is not the true indicator of the abrasive cost to the end user. A grinding ratio (G-ratio), which is volume of material removed per unit volume of disc wear, is the most conclusive testing procedure to determine overall cost because it takes into account stock removal while factoring in the cost of the product and labor rate.

End users should also try to include new, improved products in their testing process—even if they look different from the discs they have used in the past. Sometimes these products aren’t considered because any upgrades often require altering a product’s appearance. For example, in the manufacturing process of resin fiber discs, quality can be enhanced by modifying a product formula, which in turn, could mean the improved discs are a different color. Subsequent in-house testing confirms the improved product quality, but the real test lies in the opinion of the user. In many cases, the product is perceived as not being as good as the original formula because “it looks different.”

One way to overcome the psychological ramifications involved in a product change is to conduct market research. Provide key end users with product samples of the new product and an in-depth explanation of why the changes were made and the advantages the new product provides. Some distributors will object to product changes, but if the changes/enhancements are approved by the end user, distributors will have no choice but to approve as well.

At Gemtex Abrasives, we address the diversified coated abrasives market with a dual approach. First, we offer a variety of product configurations such as Trim Kut, Grind R and quick-change attachments in a multitude of minerals formulated for a broad spectrum of metal grinding applications.

Equally important, though, is the ability to provide product configurations manufactured with proprietary formulations for use on specialty metals for a wide variety of applications. We work closely with end users to develop products that offer the best cost-effective solution for their working environment. In some instances, new formulations are born from the user’s requirements for increased quality, durability and productivity.

Much like the cutting tool industry, we also are constantly experimenting with ways to reduce heat buildup generated in coated abrasive applications involving exotic metals with high tensile strength and metals with low melting temperatures like aluminum. The challenge, and always the priority, is to provide the highest quality product at the most competitive price.

There is a growing demand for unique products that perform multiple functions, are adaptable for various applications and are available in a multitude of specifications to accommodate a large spectrum of potential applications. With a strong emphasis on safety, end users also have a need for abrasives with “attachment flexibility.” It is important for abrasive manufacturers to task their R&D departments to continue to develop products with specifications that increase productivity at the end-user level. 

Frank Prenda is the vice president sales and marketing at Gemtex Abrasives.

Gemtex Abrasives
Toronto, Canada
800/387-5100