PRACTICAL MANUAL SURFACE FINISHING RUSTPROOF

Transcription

PRACTICAL MANUAL
SURFACE FINISHING
RUSTPROOF
STAINLESS STEEL
CONTENTS
side
Fundamentals
7–22
Surface/sheet metal
23–54
Industrial finish
24–36
Polished
37–45
Unworked
46–54
Circular tube
Industrial finish
Polished
55–108
56–77
78–108
Square tube
109–158
Industrial finish
110–135
Polished
136–158
Cleaning and care
159–165
Products
167–183
PRACTICAL MANUAL SURFACE FINISHING RUSTPROOF STAINLESS STEEL
3
APPLICATION OVERVIEW
Surface Finishing, Stainless steel, Rustproof:
Surface/sheet metal
Page(s)
Industrial finish
1
2
3
4
5
6
Restoring damaged surface
Removing weld seam – matching of grinding profile
Removing corner weld seam – matching of grinding profile
Chemical and electrical removal of tarnishing
Mechanical removal of tarnishing (Variant 1)
Mechanical removal of tarnishing (Variant 2)
24–26
27–29
30–31
32–33
34–35
36
Polished
1 Flaws on sheet metal
2 Butt-welded sheet metal
3 Butt-welded sheet metal
Removing weld seam – polishing
37–39
40–41
42–45
Unworked
1
2
3
4
Butt-welded sheet metal
Unworked sheet metal
Flaws on sheet metal
Removing weld seam – creating the grinding profile
Mechanical removal of tarnishing
Creating missing grinding profile
46–48
49
50–51
52–54
Initial situation
Work steps from – up to and including
Circular tube
4
Initial situation
Flaws on sheet metal
Sheet metal welded at an angle (90°)
Industrial finish
1
2
3
4
5
6
7
8
9
Butt-welded tubes
Miter-welded tubes
Butt-welded sheet tubes
Welded-in 90° elbow
Welded-on end piece (cover)
Tube welded onto plate
Tubes welded onto plate
Saddle seam
Miter-welded tubes
Mechanical removal of tarnishing – matching of grinding profile
Mechanical removal of tarnishing – matching of grinding profile
Removing saddle seam – matching of grinding profile
Removing corner / miter / fillet seam –
matching of grinding profile
Polished
1
2
3
4
5
6
Butt-welded tubes
Welded-in 90° elbow
Tube welded onto plate
Saddle seam
Tubes miter-welded together
Mechanical removal of weld seam – polishing
Removing saddle seam – polishing
Removing corner / miter / fillet seam – polishing
Page(s)
56–57
58–60
61–62
63–65
66–67
68
69–71
72–74
75–77
78–81
82–87
88–92
93–97
98–101
102–108
Square tube
Initial situation
Page(s)
Industrial finish
1
2
3
4
5
6
Butt-welded tubes
Miter-welded tubes
Butt-welded sheet tubes
Tubes welded in T shape
Welded frame
Removing weld / fillet seam – matching of grinding profile
Removing corner / miter / fillet seam –
matching of grinding profile
110–111
112–115
116–117
118–123
124–128
129–135
Polished
1
2
3
4
5
Butt-welded tubes
Butt-welded tubes
Butt-welded tubes
Tubes welded in T shape
Tubes miter-welded together (90°)
Removing weld / fillet seam – polishing
Removing corner / miter / fillet seam – polishing
136–137
138–139
140–143
144–149
150–158
Initial situation
Page(s)
Very dirty/slight rust film
Slightly dirty
Slightly dirty
Dirty tube
Cleaning
Cleaning and care
Cleaning
Cleaning
160–161
162–163
164
165
Cleaning
and care
1
2
3
4
5
Fundamentals
Fundamentals
PREFACE
Professional finishing of stainless steel surfaces represents a particular
challenge for the user. In addition to good training, skill and experience,
it is above all the machines, tools and abrasive media used that play a
decisive role in achieving excellent results.
With this practical manual, Würth intents to illustrate that very good
results are possible with a very manageable number of top-class products.
Reducing the number of products to just a few means that you maintain an
overview and keep costs in check, thereby allowing you to perfect your
handling of the tools and the abrasive media.
That's why we decided to also describe even repeated work steps in full
with photos and text for each new initial situation.
Of course, in addition to these products that are named in the brochure,
we also carry many other interesting finishing and polishing media in our
range. You can find these in our online catalogs at www.wuerth.de or in
our printed customer catalog "THE WÜRTH“.
The practical manual that you now hold in your hands is the result of many
intensive discussions with customers. A common request was for working
instructions illustrated with photos. In addition, each of these descriptions
is intended to be self-contained so that the relevant pages can be copied
when necessary, and hung up at the relevant workstation within your
company.
8
Fundamentals
1. INTRODUCTION AND FUNDAMENTALS
1.1 What is rustproof steel?
A group of iron alloys with ≥ 10.5 % chromium and ≤ 1.2 %
carbon that form a self-regenerating surface layer known as the "passive
layer".
Even if the rustproof steel is heavily scratched or otherwise damaged, this
passive layer, just a few atoms thick, regenerates in an instant under the
influence of oxygen from the air or water. This explains why rustproof steel
requires neither coatings nor other forms of surface protection.
A clean surface is a prerequisite for functioning passivation. Tarnishing,
greases or other contamination interfere with this process and must
therefore be removed as completely as possible.
Tip for pros: Mechanically finished surfaces therefore must also not be
treated immediately with care products such as stainless steel care oil, as
this impairs the surface's self-healing process (passivation).
the related fields:
• A modern, attractive appearance
• Hygiene and ease of cleaning
• Corrosion resistance
• Durability
• Compatibility with foodstuffs
• Ease of processing and
• Recyclability
That's why architects, planners and contractor companies often use
rustproof steel in architecture, metal construction (for handrails and
railings), for street furniture, in large kitchens, in the foodstuffs industry, in
catering establishments and in domestic utensils.
Rustproof steels display a range of properties that makes them particularly
suitable for decorative and load-bearing components in construction and
1.2 Stainless steel types
Austenitic types
Ferritic types
Martensitic types
Duplex steels
• Iron-chrome-nickel-(molybdenum) alloys
• Iron-chromium alloys
• Iron-chromium alloys
• Iron-chromium-nickel alloys with
a mixed austenitic-ferritic structure
• 18 % Cr, 8 % Ni*
• Carbon < 0.1 %
• Non-magnetic on delivery
• Material No. *1.4301/304
(1.4401/316)
• 17 % Cr*
• 22 % Cr, 5 % Ni, 3 % Mo*
• Carbon < 0.1 %
• Carbon > 0.1 %
• magnetic
• magnetic and hardenable
• Most common type: EN *1.4016
• magnetic
• Most common type: *1.4462
• 1.4571 (V4A)
The austenitic type is used 65 % of the time, and so can be referred
to as the "standard type". This type is commonly referred to as 18/8,
18/10 or V2A (V4A).
The alloy composition can be adjusted so that custom properties are
achieved. These properties can be assigned via the corresponding
material numbers:
The martensitic type is primarily used due to its high resistance to wear
and its cutting efficiency (e.g. razor blades).
The ferritic type is mainly used in slightly corrosive environments where
visual appearance is less important.
Duplex steels are stronger and more resistant to corrosion.
• Suitability for welding (e.g. 1.4541)
• Corrosion resistance (e.g. 1.4401)
• Mechanical properties (e.g. 1.4315)
• Oxidation resistance (e.g. 1.4828)
9
Fundamentals
1.3 Common surfaces and delivery conditions
1D: Hot-rolled, annealed, pickled
2B: Cold-rolled, annealed, pickled,
slightly re-rolled
2H: Work-hardened
2R: Cold-rolled, bright annealed,
possibly slightly re-rolled
Photos: euro inox, Brussels / www.euro-inox.org
1.4 Basic recommendations for handling rustproof stainless steel
• Do not store rustproof stainless steel and unalloyed/low-alloy steels in the same room
• Workplaces in different rooms
• Keep abrasive media separate at all times. Abrasive media that have been used on unalloyed/low-alloy steels
must never be re-used on rustproof steel
10
Fundamentals
1.5 Requirements for optimum surface finishing results
Surface finishing by grinding and polishing requires particular attention if the component is to attain its optimum function and service life. At the same time,
this final work time represents the fabricator's seal of quality on the product and, if done correctly, allows the additional benefits of rustproof steel to be
emphasized.
A few points must be observed in advance for high-quality surface finishing:
• As early as when planning the work, consideration should be given
as to whether a component can be worked at all following installation.
In certain installation situations, only limited surface reworking is
possible or is no longer possible at all.
• The correct selection of material types, particularly in the case
of smooth high-sheen surfaces, plays a major role. The types 1.4541
and 1.4571 are of limited suitability for decorative surfaces, because
the titanium in the alloy causes streaking during grinding.
• Bent tubes or size differences between the tube and the weld elbow
inevitably cause unevenness.
• Pay attention to precision as early as when cutting the material to
size. For example, if the miter cuts are not made precisely, the accuracy
of fit later will be poor.
• Perfect weld seams are crucial for perfect grinding and polishing
results. Serious welding errors can no longer be remedied during
grinding. For example, "sunken" weld seams caused by incorrect
welding equipment settings are a problem.
• Selecting the correct grinding method, equipment and media
depends on the initial state of the workpiece, accessibility of the surface
to be treated and the desired result.
• Purchase as many parts as possible ready-ground. Protect the surfaces
from damage and store them correctly.
Sunken weld seam: Here, the weld seam is still partly present after grinding has been done.
However, the material to the left and right of the weld seam is already significantly worn away → it is impossible to attain an exact surface.
11
Fundamentals
2. EXPLANATION OF TERMS
2.1 Grinding
Grinding is a mechanical process in which material is removed. When working a weld seam or flaw, always try to start with as fine a grain as possible. If the
amount of removal is not sufficient, change over to the next coarsest grain. A grain that is too coarse can cause damage that cannot be remedied, or that can
be remedied only with major effort.
2.2 Grinding profile
An individual grinding profile is produced depending on the grain size, the texture of the abrasive medium and the grinding direction.
Here, attention must be paid to the original grinding direction of the workpiece.
2.3 Surface roughness Ra
The surface quality is an expression of the surface roughness. The Ra value (mean roughness value) describes the surface roughness. Roughness is a term from
surface physics that refers to the unevenness of the surface height. There are different calculation methods for quantitative characterization of the roughness,
each of which takes into account the various properties of the surface.
2.4 Overlapping grinding
With each increasingly fine grain, do not grind only on the previously ground point but instead grind outwards, moving out into the undamaged grinding
profile (edge zones) so as to obtain smooth transitions. During this process, the press-on pressure decreases outwards.
12
Fundamentals
2.5 Cross grinding/across the grain
In principle this means that the individual grinding/polishing processes are carried out in a "cross pattern", i.e. if possible at a 90° angle to the last,
preceding work step. Grinding/polishing in the finish/longitudinal direction represents the last step.
1st work step
2nd work step "across"
Above all, removing the traces of grinding by means of going across the grain is extremely important as the final work step before polishing.
During polishing itself, we also start across the last grinding profile.
2.6 Finish grinding
The last work step for producing the desired grinding profile (surface roughness).
13
Fundamentals
2.7 Matching
After the weld seam / flaw has been removed, we start the process of approaching the original grinding profile: The grain becomes finer with each grinding
operation. The final stage is matching. The transitions from the grinding point into the surrounding grinding profile are now adjusted, i.e. matched.
2.8 Polishing
Polishing describes a decorative treatment that removes only a small amount of material.
2.9 Contact angle
The angle between the grinding plate and the workpiece is referred to as the contact angle. Ideally it should be approximately 10–15°.
2.10 Press-on pressure with heat generation
During working, the press-on pressure and the resulting surface temperature must be kept to a minimum. This is achieved by a shorter dwell time or, if possible, by
underlaying with aluminium sheets. Otherwise scoring can occur that can be eliminated only with difficulty afterwards.
14
Fundamentals
2.11 Speeds
With fleece products, the grinding profile can be greatly influenced via the speed and the press-on pressure. In this brochure we provide for each application
recommendations as to which speed range should be worked in with the respective abrasive and polishing media.
Speed table of the machines used / Given in rpm:
Level
KNS 150-E Fillet Weld Grinder
Polishing Machine PM 200-E
EWS 14-125 INOX Angle Grinder
1
1.300
900
2.100
2
1.800
1.200
3.000
3
2.400
1.500
3.800
4
2.900
1.900
4.500
5
3.500
2.200
5.300
6
4.000
2.500
7.500
2.12 Degrees of fineness/grains
The table below is intended to provide an indication as to how the grinding profiles of various abrasive media can be approximately compared.
Please note: The grains/grinding profiles are not directly comparable.
Grain size/grinding profile
TRIZACT®
Fleece
K120
A160
coarse
K220
A100
medium
K280
A65
fine
K400
A45
super fine
K600
A30
--
K1200
A16
--
TRIZACT® is a registered trademark of the 3M Company in the US.
15
Fundamentals
3. HANDLING
Tips for handling our own products used in this practical manual
3.1 Tube belt grinder assembly RBS 650
The tube belt grinder assembly RBS 650 can be used on both speedcontrolled angle grinders with a Euro neck (e.g. EWS 14-125 INOX) or
on compatible polishing machines (e.g. PM 200-E). The design of the
assembly allows grinding in awkward locations such as installed handrails
(4 cm wall clearance). The wrap angle is less than with the usual tube
grinding machines on the market. This brings with it the advantage of
lower grinding temperatures and less heating of the material. The unit can
be used to work on round materials of dia. 8–250 mm (360°).
Pay attention to the following when working on elbows: The contact of the
fixed guide rollers in the outer elbow prevents the belt from jumping off
and allows the machine to be gently guided at a 90° angle to the tube.
The fixed guide rollers should be placed on in the elbow
16
Fundamentals
3.2 Segmented grinding disk OSF
The one-step finish disk (OSF) is designed for direct use on variable-speed angle and fillet weld grinders.
It provides a combination of fast material removal and perfect surface quality in the tube area.
Major advantage: Weld seams in the tube area can be removed in one work step up to the finish grind.
3 IN 1:
1. Smoothing out the weld seam
2. Matching
3. Finish grinding
1. Press-on pressure:
Controlled press-on pressure is very important for
the result. Work with light pressure.
2. Contact angle:
Work with a contact angle of 10°-15° (angle
between disk and workpiece) to increase the
contact surface.
3. Grinding direction:
Grind with the OSF disk along the length of
the workpiece. The grinding direction used for
the OSF disk is especially important. The disk's
direction of rotation is the direction of the desired
grinding profile.
17
Fundamentals
3.3 Hard-pressed compact fleece disk
This disk is available in different versions for use on fillet weld and angle grinders.
During use it is important to always only use this disk on its end. It is recommended to grind in one direction (e. g. pulling) only. It is particularly suitable for removing
tarnishing in the vicinity of weld seams, since the hard-compressed compact fleece disk always achieves uniform surface results.
3.4 Self-adhesive stainless steel strip
The stainless steel strip has two adhesive strips on the back and can be used
more than once. It is used to protect the ground or polished surfaces and for
creating a precise miter.
Material: 1.4404/thickness: 0.15 mm.
18
During grinding (e. g. with a folded sanding fleece roller or folded sanding
fleece ring), attention must be paid to the rotation direction. Otherwise the
roller can lift the stainless steel strip. There is a risk of injury.
Fundamentals
3.5 Folded sanding fleece ring / roller
The products are hand-made and can therefore be slightly uneven. This can
result in shadows during grinding. In this case the roller must be cleaned in
order to continue working. This process gives rise to a "soft" (fine) and a "hard"
(coarse) surface structure on the roller. The grinding process should be initially
commenced with the coarse side. If shadows or transitions are then apparent,
it is necessary to change over to the "soft" side. When doing so, vary the
speed and the press-on pressure.
The following always applies to fleece products such as these:
• At high speed, coarse grain has a finer effect,
and at low speed fine grain has a coarser effect.
• The press-on pressure can influence the grinding profile.
3.6 TRIZACT®
TRIZACT® is a textured abrasive medium for refining and finishing. The
even three-dimensional pyramid grain structure ensures that the abrasive
medium wears evenly. This means that the achieved surface quality
(surface roughness) remains absolutely constant right from the start until
the abrasive grain is worn down. With an ordinary abrasive medium
on the other hand, the surface roughness differs as the abrasive grain is
increasingly worn down.
TRIZACT® means: aggressive grinding, low surface roughness, a very fine
grinding profile and above all a much longer service life combined with a
constant surface quality.
For an optimum result, attention must be paid to the sequence of the
degrees of fineness, i.e. overlapping working of flaws, starting with as fine
a grain as possible. Observing the recommended speed is important here.
TRIZACT® is a registered trademark of the 3M Company in the US.
Three-dimensional pyramid structure
19
Fundamentals
3.7 Selecting the right support plate
The hard support plate (black) is used to remove the weld seam because it enables pressure to be applied to the seam.
This means that only the weld seam is removed, without recesses being ground to its left and right.
The medium-hard support plate (red) is selected for grinding out flaws in order to obtain soft transitions.
The soft support plate (gray) is used when slight flaws on metal sheets must be removed.
Removing a weld seam:
Wrong: soft plate
Right: hard plate
3.8 Pay attention to the machine's rotation direction when grinding edges
Wrong
Right
In order to obtain level surfaces, the grinding plate should not run against the edge.
20
Fundamentals
4. WORK PROTECTION AND
WORK SAFETY
The surface finishing of stainless steels produces abrasion dust. Although
there are no special limit values for rustproof stainless steel, the amount
of dust must always be limited as with unalloyed/low-alloy steels. These
protective measures must be taken in order to prevent negative effects that
can damage people's health.
The safety regulations stipulated by the employers' liability insurance
association must also be observed when handling the machines required
for surface finishing. Würth supplies a wide range of personal safety
equipment as well as work clothes and footwear, and for safety at the
workplace.
ARBEITSSCHUTZ
Für Ihre Sicherheit machen wir uns stark
Arbeitsbekleidung
Arbeitsschuhe
Persönliche
Schutzausrüstung
21
Fundamentals
Sources:
Fact sheet 968 Mechanical Surface Treatment of Rustproof Steels in Decorative Applications
Fact Sheet 803 What is rustproof steel?
euro inox, Brussels/www.euro-inox.org
Wikipedia: The free encyclopedia: www.wikipedia.de
22
Surface/sheet metal
Surface/sheet metal
INDUSTRIAL FINISH
(grinding profile K240)
1 Restoring damaged surface
Initial situation: Flaws on metal sheet
Close-up view
Remove flaw
Grinding direction
TIP FOR PROS:
Topreventdistortionofthesheetduetoheat
production,itispossibletounderlayitwithan
aluminumorcopperplate
24
•Asoft support plate (gray) with a fabric Velcro disk
TRIZACT®mustbeusedinordertoobtainsmoothtransitions
•Machinerecommendation:Electric Polishing Machine
•Startwiththefinestgrain.Ifsuccessisnotachievedwiththis,change
overtothenexthighesti.e.coarsergrain
•Toremaininthegrindingprofile,adapttherotationdirectionofthedisk
tothegrindingprofile
•Workwithcrossgrindingintheeventofdeepscratches.Thefinalwork
stepwithTRIZACT® A16mustagainbeinthegrindingdirection
Surface/sheet metal
•Thegrindingpointmustrunouttowardsthe
edgesoftheflaw.Thisoverlappinggrinding
intotheundamagedgrindingprofilecreates
anoptimumstartingpositionforthesubsequent
finishgrind
•Theflawmustbecompletelygroundoutinthe
firstworkstep
•Recommendedspeed:approx.2,500rpm/level
6
•Applyaslittlepressureaspossible(generates
heat!)
•Contactangleoftheadhesionsupportplate:
asflataspossible(5–10°)
Interim result
Matching the grinding profile at the flaw
•Withtheelectricpolishingmachineandthe
orange folded grinding fleece ring ata
speedofapproximately900rpm/level1,
createthegrindingprofileonthepreviously
workedflawinthegrindingdirectionwith
somewhatgreaterpressure
25
Surface/sheet metal
Finish
TIP FOR PROS:
Iftherearestillshadowsvisibleonthemetal
sheet,therollercanbecleanedinorderto
continueworking
Final result
Products
•ElectricpolishingmachinePM200-E,Art. No. 0702 453 0
•FabricVelcrodiskTRIZACT®A16,Art. No. 0573 412 120
•HolderforsidehandleforPM200-E,Art. No. 0702 451 015
•HandguardforPM200-E,Art. No. 0702 489 906
•Orangefoldedgrindingfleecering125x50mmxM14,Art. No. 0672 911 080
•Orangefoldedgrindingfleeceroller100x100x19mm,Art. No. 0672 919 080
•ClampingmandrelforPM200-E,Art. No. 0702 451 020
•SoftsupportplateforVelcrodisks(gray),Art. No. 0586 641 125
26
•Replacethefoldedgrindingfleeceringwiththe
orange folded grinding fleece roller
(withclampingmandrel)
•Foranoptimumresult,startatalowspeed(900
rpm/level1)andincreaseitslowly(uptomax.
2,500rpm/level6)whileconstantlyreducing
thepressure
Surface/sheet metal
2 Removing weld seam - matching of grinding profile
Initial situation: Metal sheets butt-welded together (e.g. on extractor hoods)
TIP FOR PROS:
Underlaywithanaluminumplateto
dissipatetheheatgeneratedbygrinding
Removing the weld seam
•RemovetheweldseamwiththeINOX angle
grinder, hard support plate for Velcro
disks (black) and fabric Velcro disk
(ceramic grain).Ifpossible,startwithafine
grain(optimum:K120).Iftheweldseamistoo
strong,usecoarsergrain(K80)
•Recommendedspeed:3,800–4,500rpm/
level3–4
•Workwithanappropriatepress-onpressurein
ordertopreventthediskfromvitrifying
27
Surface/sheet metal
Preliminary work for grinding profile matching
•Fitthesupport plate for medium Velcro
disks (red) ontotheINOXanglegrinder.
•Usethefabric Velcro disk TRIZACT®
A100tocompletelyeliminatethetracesof
grindingfromthepreliminarywork(speed
approx.3,000–4,000rpm/level2–3)
•Nextreducethesurfaceroughnesswitha
fabric Velcro disk TRIZACT® A45.If
thesurfaceroughnessistoogreat,continue
workingwithA30
Matching of grinding profile
•Withtheelectric polishing machine
andtheorange folded grinding fleece
ring ataspeedof900rpm/level1,
createthegrindingprofileinthegrinding
directionwithsomewhatstrongerpressure
28
Surface/sheet metal
Finish
•Fitthe orange folded grinding fleece
roller (withclampingmandrel)ontothe
electricpolishingmachine
•Foranoptimumresult,startatalow
speed(900rpm/level1)andincreaseitslowly
(uptomax.2,500rpm/level6)whileconstantly
reducingthepressure
Final result
TIP FOR PROS:
Iftherearestillshadowsvisibleonthemetal
sheet,therollercanberemoved
Products
•ElectricanglegrinderEWS14-125INOX,Art. No. 0702 478 0
•FabricVelcrodisk,ceramicgrain,Art. No. 0573 312 …
•FabricVelcrodisks,TRIZACT®A100/A65/A45/A30,Art. No. 0573 412 …
•Orangefoldedgrindingfleeceroller100x100x19mm,Art. No. 0672 919 080
•ClampingmandrelforPM200-E,Art. No. 0702 451 020
•HardsupportplateforVelcrodisks(black),Art. No. 0586 643 125
•MediumsupportplateforVelcrodisks(red),Art. No. 0586 642 125
29
Surface/sheet metal
3 Removing corner weld seam - matching of grinding profile
Initial situation: Metal sheets welded to each other (90°)
•RemovetheweldseamwiththeINOX angle grinder, hard
support plate for Velcro disks (black)and fabric Velcro
disk (ceramic grain) K120.
•Recommendedspeed:approx.3,800-4,500rpm/level3or4
•Important: Itisessentialtomakesurethatonlytheweldseamis
ground.Themorethediskisusedonthesurfacetotheleftandrightof
theweldseam,thepoorertheendresult
Interim result
30
Surface/sheet metal
•Usetheelectric polishing machine andthe orange folded
grinding fleece ring tomatchthegrindingprofile
•Attention!Payattentiontotherotationdirectionofthefoldedgrinding
fleeceringsothatitdoesnothittheedge
•Recommendedspeed:900rpm/level1
Final result
Products
•FabricVelcrodisk(ceramicgrain)K120,Art. No. 0573 312 012
•Orangefoldedgrindingfleecering,Art. No. 0672 911 080
•HardsupportplateforfabricVelcrodisks(black),Art. No. 0586 643 125
31
Surface/sheet metal
4 Chemical/electrical removal of tarnishing
Initial situation: Metal sheets butt-welded to each other
Cleaning
•Fitthematchingfeltfromthecleaning setontothehandleofthe
WELNOX® cleaning device
•SettheWELNOX®cleaningdeviceto"Cleaning"withtherotaryknob
•Fitagroundterminaltotheworkpiece
•Fitthecleaning solution for stainless steeltothehandpiece
•SwitchontheWELNOX®cleaningdevice
•Soakthecleaningfeltthoroughly
32
•Placeitontotheweldseamtobecleaned
•Removethetarnishingbyslowlymovingitovertheweldseam
•Attention!Thefeltpadmustalwaysbecompletelysoakedwithliquid,as
otherwisetheservicelifewillbeconsiderablyshortened.
•Useadampclothtowipeoffthecleaningsolutioninordertoprevent
tarnishing
Surface/sheet metal
Final result
TIP FOR PROS:
Ifgrayedges(zonesofheatinfluence)
remain,theycanberemovedwiththe
polishingset
Products
•CleaningsetICSS300-P,Art. No. 0984 250 901(includedwiththeWELNOX®cleaningdevice)
•CleaningsolutionforstainlesssteelArt. No. 0893 984 800(includedwiththeWELNOX®cleaningdevice)
•WELNOX®cleaningdeviceICSS300-P,Art. No. 0702 353 550
•Optional:PolishingSetICSS300-P,Art. No. 0984 250 902
33
Surface/sheet metal
5 Mechanical removal of tarnishing
Removing tarnishing
•Usetheangle grinder INOXandthe
hard-pressed compact fleece disk
with fabric plate tocleantheweldseamand
removethetarnishing
•Speed:max.3,800min/level3
Final result
34
Surface/sheet metal
TIP FOR PROS:
Toobtainaclean,sharpedgetotherestof
thegrindingprofile,stainlesssteelstripcanbe
usedtomaskoffpriortogrinding
Products
•Self-adhesivestainlesssteelstrip,Art. No. 0672 101 003
•Hard-pressedcompactfleecediskwithfabricplate,hardness5(soft)dia.125mm,Art. No. 0585 012 348
35
Surface/sheet metal
Removing tarnishing
•Usetheelectric polishing machine and
the orange folded grinding fleece ring
at900rpm/level1inthegrindingdirectionto
removethetarnishingandcleantheweldseam
Final result
Advantage:Hardlyanytransitionsintothesheet'soriginalgrindingprofilearediscernable
Products
36
Surface/sheet metal
POLISHED SHEETS
Initial situation: Flaws on surface
Remove flaw
•Usetheelectric polishing machine,themedium support plate
for Velcro disks (red)andTRIZACT fabric Velcro disks®to
removetheflaw
•Alwaysstartwithasfineagrainaspossiblesoasnottocreateany
unnecessarysurfaceroughness.Thegrainoftheabrasivemedium
mustbeselectedaccordingtothedepthoftheflaw(inourcase
startwithA100)
•Next,performtheinterimgrindoverlappingoutwardsintothe
undamagedsurfacewithA65, A45, A30inturn,andwhendoingso
removealltracesofgrindingleftbehindfromtheprecedingworkstep.
•Finallyandonceagainoverlapping,useA16tocompletethe
preparatoryworkforthehigh-glosspolishing
•Important:Asflatacontactangleaspossible,approx.10–15°
•Recommendedspeed:approx.1,500rpm/level3
37
Surface/sheet metal
Interim result
Polishing
•Fitthehard polishing ring ontotheelectric
polishingmachine
•Applythewhite polishing pasteatlow
speed(900rpm/level1)directlyontothehard
polishingring
•Duringpolishing,alwayspolish"across
thegrain",i.e.inthefirstworkstepagainst
thegrindingdirectionofthelastgrindwith
TRIZACT®A16
•Next,duringpolishing,thewaythemachineis
heldisrepeatedlychangedinordertoobtain
this"acrossthegrain"
•Important: Alltracesofgrindingmustbe
polishedoutduringthisworkstep
•Next,removethepolishingpasteresiduewith
Vienna polishing chalk andmicro
active clothandthenrepeatthepolishing
processwithblue buffing paste and the
soft polishing ringuntilyouobtainamirror
sheen
•Recommendedspeed:approx.2,000-2,500
rpm/level5-6
•Thefinalstepispolishinginthelongitudinal
directionatareducedspeedof
approx.1,200min-1/level2
38
Surface/sheet metal
Removing polishing paste residues
•Finally,removethepolishingpasteresiduewith
Viennapolishingchalkandmicroactivecloth
Final result
Products
•Bluebuffingpaste,Art. No. 0673 05 3
•FabricVelcrodisk,TRIZACT®A100/A65/A45/A30/A16,Art. No. 0573 412 …
•Professionalmicroactivecloth,blue,Art. No. 0899 900 131
•Whitepolishingpaste,Art. No. 0673 05 1
•Hardpolishingring,dia.200mm, Art. No. 0673 03 200
•Softpolishingring,dia.200mm, Art. No. 0673 04 200
•MediumsupportplateforfabricVelcrodisks(red),Art. No. 0586 642 125
•Viennapolishingchalk,Art. No. 0893 121 100
39
Surface/sheet metal
Removing tarnishing
• Fitthematching feltfromthepolishing
setontotheWELNOX® cleaning device
andsetto"Polish"withtherotaryknob
•Fitthepolishing solutiontothehandpiece
•SwitchontheWELNOX®cleaningdevice
•Soakthepolishingfeltthoroughly
•Removethetarnishingbyslowlymovingitover
theweldseam
•Attention!Thefeltpadmustalwaysbe
completelysoakedwithliquid,asotherwisethe
servicelifewillbeconsiderablyshortened
•Note:Duetotheriskofburningin,donot
remaininonespotfortoolong
•Useadampclothtowipeoffthepolishing
solutioninordertopreventtarnishing
40
Surface/sheet metal
Final result
Products
•PolishingsetICSS300-P,Art. No. 0984 250 902
•Polishingsolution,Art. No. 0893 984 803
•WELNOX®cleaningdeviceICSS300-P,Art. No. 0702 353 550
41
Surface/sheet metal
3 Removing weld seam - polishing
•Removetheweldseamwiththeelectric polishing machine, hard
support plate for Velcro disks (black)and the fabric Velcro
disk TRIZACT® A160 ..
42
Surface/sheet metal
Reducing the surface roughness
•Next,replacethehardsupportplatewiththemedium support plate
for Velcro disks (red)andcontinuegrindingwithcrossgrinding
usingthe fabric Velcro disks TRIZACT® A65, A45, A30, A16
inturnuntilafine,polishablesurfaceisobtained
•Important:Everytimetheabrasivemediumischanged,grind
overlappingintotheundamagedpolishedsurface
Interim result
43
Surface/sheet metal
Polishing
•Fit the hard polishing ring ontotheelectricpolishingmachine
•Applythe white polishing pasteatlowspeed(900rpm/level1)
directlyontothehardpolishingring
•Duringpolishing,alwayspolish"acrossthegrain",i.e.inthefirstwork
stepagainstthegrindingdirectionofthelastgrindwithTRIZACT®A16
•Next,duringpolishing,thewaythemachineisheldisrepeatedly
changedinordertoobtainthis"acrossthegrain"
•Important:All traces of grinding must be polished out
during this work step
•Next,removethepolishingpasteresiduewithVienna
polishing chalk andmicro active clothandthenrepeatthe
polishingprocesswith blue buffing paste and the soft polishing
ringuntilyouobtainamirrorsheen
•Recommendedspeed:approx.2,000-2,500rpm/level5-6
•Thefinalstepispolishinginthelongitudinaldirectionatareduced
speedofapprox.1,200rpm/level2
44
Surface/sheet metal
•Finally,removethepolishingpasteresiduewith
Viennapolishingchalkandmicroactivecloth.
Final result
Products
•FabricVelcrodisk,TRIZACT®A160/A65/A45/A30/A16,Art. No. 0573 412 …
45
Surface/sheet metal
UNWORKED METAL SHEET
1 Removing weld seam - creating grinding profile
TIP FOR PROS:
Underlaywithanaluminumplateto
dissipatetheheatgeneratedbygrinding
•RemovetheweldseamwiththeINOX angle
grinder, hard support plate for Velcro
disks (black)andfabric Velcro disk
(ceramic grain) K120.
•Recommendedspeed:4,500rpm/level4
•Workwithanappropriatepress-onpressurein
ordertopreventthediskfromvitrifying
46
Surface/sheet metal
Interim result
Creating the grinding profile
•Fitthe medium support plate for Velcro
disks (red)
A100tocompletelyremovethetracesof
grindingfromthepreviouswork
•Recommendedspeed3,000–3,800rpm/
level2–3
47
Surface/sheet metal
•Maskoffwithstainless steel striptothe
leftandrightoftheweldseam
the orange folded grinding fleece ring
ataspeedof900rpm/level1tocreatethe
grindingprofileinthegrindingdirectionwith
somewhatstrongerpressure
•Removethestainlesssteelstrip
•Ifnecessary,usebrakecleanertocarefully
removeanyadhesiveresidue
Final result
Products
•FabricVelcrodisk,ceramicgrainTRIZACT®A100,Art. No. 0573 412 022
48
Surface/sheet metal
TIP FOR PROS:
Underlaywithanaluminumplatetodissipate
theheatgeneratedbygrinding
Removing tarnishing
•Tarnishingcanberemovedinoneworkstep
withINOX angle grinder andhardpressed compact fleece disk with
fabric plate
•Recommendedspeed:3,000–3,800rpm/
level2-3
Final result
Products
•Hard-pressedcompactfleecediskwithfabricplate,hardness5(soft)dia.125mm,Art. No. 0585 012 348
49
Surface/sheet metal
3 Creating missing grinding profile
Initial situation: Unworked metal sheet
TIP FOR PROS:
Sothattheedgesarenotroundedduringgrinding,
ametalsheetcanbepositionedflushbeforehand
•Usetheelectric polishing machineand
orange folded grinding fleece rollerto
produceasmoothgrindingprofileslowlyand
alwaysleadinginthesamedirection
•Note:Thegrindingprofileisdependenton
thespeedandthepress-onpressure
50
Surface/sheet metal
Final result
Products
•Orangefoldedgrindingfleeceroller,Art. No. 0672 919 080
•ClampingmandrelM14,Art. No. 0702 451 020
51
Surface/sheet metal
Initial situation: Unworked metal sheet with flaws
Removing flaws and rolling skin
TIP FOR PROS:
•Payattentiontotherotationdirectionofthe
expansionroller
(arrowprintedontheside)andmachine!
•Ensurepreciseguidanceduringgrinding,
otherwisetiltingandthereforestreakingcanoccur
•Fit the expansion rollerbymeansofthe clamping mandrel
ontotheelectric polishing machine
•RemovethedamagedsurfaceandrollingskinwiththeTRIZACT
fabric grinding sleeve® A160
52
•Hint:IftheflawscannotberemovedwithTRIZACT®A160,ceramic
graingrindingsleeves(K80–120)mustbeusedforgrindingbeforethe
finegrindingisperformedwithTRIZACT®A160
Surface/sheet metal
Interim result
•Usetheelectricpolishingmachineandorange folded grinding
fleece rollertoproduceasmoothgrindingprofileslowlyandalways
leadinginthesamedirection
53
Surface/sheet metal
Final result
Products
•Expansionroller100x100mm,Art. No. 0702 460 005
•FabricgrindingsleeveTRIZACT®A160,Art. No. 0672 918 012
•Orangefoldedgrindingfleeceroller,Art. No. 0672 919 080
•Optional:Grindingsleeves,ceramicgrain(dependentonthematerial),Art. No. 0672 917…
54
Circular tube
Circular tube
INDUSTRIAL FINISH
1 Mechanical removal of tarnishing – matching of grinding profile
Initial situation: Tubes butt-welded to each other
Removing tarnishing
the orange folded grinding fleece
ring tocompletelyremovethetarnishinginthe
grindingdirection
Interim result
56
Circular tube
•Withthereclosable fleece belt,matchthe
grindingprofiletotheleftandrightoftheweld
seam
Final result
Products
•Reclosablefleecebelt,Art. No. 0585 40 180
57
Circular tube
2 Mechanical removal of tarnishing – matching of grinding profile
Initial situation: Tubes miter-welded to each other (90°)
Removing tarnishing from the fillet weld
•Usethefillet weld grinderandhard-pressed compact fleece disk,
hardness 5 (soft) 6 mm dia. 150 mmtoremovethetarnishing
58
Circular tube
Removing the tarnishing on the miter/corner seam
•Usetheangle grinder INOX andhard-pressed compact
fleece disk with fabric platetoremovethetarnishing
Finish grind
•Next,usethereclosable fleece belt to
matchthesurface
Final result
59
Circular tube
Final result
Products
•Hard-pressedcompactfleecedisk,hardness5(soft),dia.150mm,Art. No. 0585 915 243
•Hard-pressedcompactfleecediskwithfabricplate,hardness5(soft),dia.125mm,Art. No. 0585 012 348
•FilletweldgrinderKNS150-E,Art. No. 0702 515 0
60
Circular tube
•Fitthetube belt grinder assemblyontotheelectric polishing
machine.
•Completelysmoothouttheweldseamswiththeceramic grain
fabric grinding belt K60 (35 mm)
Interim result
61
Circular tube
Match the grinding profile to the finish grind
•Thenusethefabric grinding belt TRIZACT® A160tocreatethe
finishgrind
•Removeanyshadowsmanuallywiththereclosablefleecebelt
Final result
Products
•CeramicgrainfabricgrindingbeltK6035x650mm,Art. No. 0673 408 006
•FabricgrindingbeltTRIZACT®A160,Art. No. 0673 508 012
•TubebeltgrinderassemblyRBS650,Art. No. 0673 200
•Optional:Reclosablefleecebelt,Art. No. 0585 40 180
62
Circular tube
Initial situation: welded-in 90° round elbow
Removing weld seams on the outer elbow
•Fitthetube belt grinder assemblyontotheelectric polishing
machine
•Completelysmoothouttheweldseamswiththeceramic grain
fabric grinding belt K60 (35 mm)
TIP FOR PROS:
Thecontactofthefixedguiderollersintheouter
elbowpreventsthebeltfromjumpingoffand
allowsthemachinetobegentlyguidedata
90°angletothetube,therebyproducingan
exactgrindingprofile.
63
Circular tube
Removing the weld seams on the inside face
•Ontheinsideelbow,removetheweldseamwith
anarrowceramic grain fabric grinding
belt K80 (15 mm)
•Itisevenpossibletogrindfrombelowwithno
problemusingthetubebeltgrinderassembly
TIP FOR PROS:
Duetotheminimumdiameterdifferencesbetweenthe
tubeandweldelbow,itmaybenecessarytomatchthe
transitions.Thiscanbeeasilydonewiththesegmented
grindingdiskOSF
(seePage83).
•Thenusethefabric grinding belt
TRIZACT® A160tomatchthefinishgrind
64
Circular tube
Finish grind
•Usethemedium fleece grinding belt
(red-brown)ataspeedofapprox.1,500
rpm/level3tocreatethefinishgrind
•Iftheinsideelbowistoonarrow,performthe
finalgrindwithareclosablefleecebelt
Final result
Products
•Mediumfleecegrindingbelt(red-brown)35x650mm,Art. No. 0673 608 018
•Optional:Reclosablefleecebelt,Art. No. 0585 40 180
•Optional:SegmentedgrindingdiskOSF,Art. No. 0585 580 328
65
Circular tube
Initial situation: Welded-on end piece (cover) on circular tube
Removing the weld seam from below
TIP FOR PROS:
Toremaininthegrindingprofile,themachine
mustbeguidedparalleltothetube
•Completesmoothingoutoftheweldseamtothefinishgrindwiththe
INOX angle grinderandthesegmented grinding disk OSF
•Important: Asflatacontactangleaspossible,approx.10–15°
•Inordertoavoidunevenness,exertpressureonlyontheweldseam
Not like this: Machine held in the wrong way! Operator not wearing breathing protection and
protective goggles!
•Holdingthemachineinthewrongwaycausesthedisktonolongerrotateinthegrindingdirectionofthetube.Thisdestroysthegrindingprofile
66
Circular tube
Finish grind
•Usethereclosable fleece belttomatch
anyshadows
Removing the weld seam from above
•Theweldseamandthetarnishareremovedon
thecoveralso,workingwiththeINOXangle
grinderandsegmentedgrindingdiskOSFto
obtainthefinishgrind
•Recommendedspeed:approx.3,000-
3,800rpm/level2-3
Final result
Products
•SegmentedgrindingdiskOSF,Art. No. 0585 580 328
67
Circular tube
Initial situation: Tube welded onto plate
Removing tarnishing
UsetheWELNOX® cleaning deviceto
removethetarnishingasfollows:
•Fitthecleaning solution for stainless
steeltothehandpiece
•SwitchontheWElNOX®cleaningdevice
•Soakthecleaning feltthoroughly
theweldseam
•Useadampclothtowipeoffthecleaning
solutioninordertopreventtarnishing
Final result
Products
•CleaningsetICSS300-P,Art. No. 0984 250 901(includedwiththeWElNOX®cleaningdevice)
•CleaningsolutionforstainlesssteelArt. No. 0893 984 800(includedwiththeWElNOX®cleaningdevice)
•WElNOX®cleaningdeviceICSS300-P,Art. No. 0702 353 550
68
Circular tube
Initial situation: Tube welded onto plate
Removing tarnishing and weld seam
•Iftheweldseamisalsotoberemovedinadditiontothetarnishing,this
canbedoneinoneworkstepwiththefillet weld grinderandthe
hard-pressed compact fleece disk
•Toremovetheseam,selecthardness 8 (hard), 3 mm anduseitto
grindasmoothtransitionfromthetubetotheplate
•Usehardness 5 (soft), 6 mm toreducethesurfaceroughnesson
theweldseamandremovethetarnishing
Matching to the grinding profile
•Useareclosable fleece belt tomatchthegrindingprofileonthetubetothefinishgrind
69
Circular tube
Interim result
Removing traces of grinding on the base plate
•UsetheINOX angle grinder, medium
adhesive support plate (red)and
fabric Velcro disk TRIZACT® A160to
removethetracesofgrindingonthebaseplate
•Next,usethefabric Velcro disks
TRIZACT® A160, A65, A30tocreatean
increasinglyfinegrindingprofile
Creating the grinding profile on the base plate
•Maskoffthetubewithstainless steel strip
soasnottodamagethegrindingprofileonthe
tube
•Withtheelectric polishing machine and
ring,createagrindingprofileontwoopposite
sidesofthetube(fromtheuser'sviewpointto
theleftandrightofthetube)
•Pulloffthestainlesssteelstripanduse
Schleiffix K60 ontheremainingopposite
sides(fromtheuser'sviewpointinfrontofand
behindthetube)tocreatethegrindingprofile
70
Circular tube
TIP FOR PROS:
ChamfertheSchleiffixwithaknifesothat
optimummatchingispossibleinthenarrow
radiusbetweenthetubeandthebasplate
TIP FOR PROS:
Inordertoreducethecomplexreworkingonthebase
plate,aholecanbecutinthestainlesssteeladhesive
stripwithscissors.Thediametermustbeatleastaslarge
astheoutsidediameteronthetube.
Whentheadhesivetapeisstuckontothebaseplate,the
weldseamcanbegroundwithoutdamagingtheplate.
Products
•FabricVelcrodisksTRIZACT®A160/A45/A16,Art.-Nr. 0573 412 ...
•Mediumadhesivesupportplate(red),Art. No. 0586 642 125
•Hard-pressedcompactfleecedisk,hardness5(soft),6mmdia.150mm,Art. No. 0585 915 243
•Hard-pressedcompactfleecedisk,hardness8(hard),3mmdia.150mm,Art. No. 0585 915 172
•SchleiffixK60,Art. No. 0587 03 60
•Orangefoldedgrindingfleecering125x50mmxM14Art. No. 0672 911 080
71
Circular tube
8 Removing saddle seam - matching of grinding profile
Initial situation: Saddle seam
Whenremovingthesaddleseam,theparticularchallengeliesinmatching
thegrindingprofileofthehorizontalandverticaltubes.Forthis,theweld
seammustalreadyhavebeendrawnveryprecisely.Whenremovingthe
weldseam,ensurelowsurfaceroughnessrightfromthestart.
•Usethefillet seam grinder andhardpressed compact fleece disk, hardness
8 (hard), 3 mm,toremovetheweldbeads
•Important:Ensureexactguidanceofthe
diskontheweldseam,otherwiserecessesthat
cannolongerbegroundoutwilloccur
•Recommendedspeed:approx.3,500rpm/
level5
Interim result
72
Circular tube
Removing tarnishing and reducing surface roughness
•Usea hard-pressed compact fleece disk, hardness 5 (soft),
6 mmtosignificantlyreducethesurfaceroughnessandremovethe
tarnishingtotheleftandrightoftheweldseam
TIP FOR PROS:
Whenremovingthetarnishingonthetube,if
possiblealwaysgrindonlyinonedirection,i.e.
forexampleworkonlyinapullingdirection
Matching to the grinding profile up to the finish grind
•Useareclosable fleece belt (manualoperationoronthetubegrindingassembly)tomatchthegrindingprofileuptothefinishgrind
•MatchthecriticaltransitionareaonthesaddleseamwithSchleiffix
73
Circular tube
Final result
Products
•Hard-pressedcompactfleecedisks,hardness5(soft),6mm,Art. No. 0585 915 243
•Hard-pressedcompactfleecedisks,hardness8(hard),3mm,Art. No. 0585 915 172
74
Circular tube
9 Removing corner/miter/fillet seam – matching of grinding profile
Removing the weld seam on the outside
•Completesmoothingoutoftheouterweldseam
uptothefinishgrindwiththesegmented
grinding disk OSF andtheangle grinder
INOX
•Important: Asflatacontactangleas
possible,10–15°
3,500rpm/level2-3
•Inordertoavoidunevenness,exertpressure
onlyontheweldseam
•Maintainagrindingdirectionalongthelength
ofthetube,i.e.guidethemachineparalleltothe
tube,sothatthedisk'sdirectionofrotationisthe
directionofthedesiredgrindingprofile.
•Theweldseaminitiallyremainsinthefilletseam
Interim result
75
Circular tube
Removing the fillet seam
•Usethe hard-pressed compact fleece
disk, hardness 8 (hard,) 3 mmandthe
fillet seam grindertoremovetheweld
bead
•Important: Ensureexactguidanceofthe
diskontheweldseam,otherwiserecessesthat
cannolongerbegroundoutwilloccur
Reducing surface roughness and removing tarnishing
•Usethehard-pressed compact fleece
disk, hardness 5 (soft), 6 mm to
significantlyreducethesurfaceroughnessand
removethetarnishingtotheleftandrightofthe
weldseam
•Useareclosable fleece belttomatchthe
grindingprofileuptothefinishgrind
76
Circular tube
Final result
•Exactmiteratanangleof45°
Products
•Hard-pressedcompactfleecedisks,hardness5(soft),6mmdia.150mm,Art. No. 0585 915 243
•Hard-pressedcompactfleecedisks,hardness8(hard),3mmdia.150mm,Art. No. 0585 915 172
77
Circular tube
POLISHED CIRCULAR TUBE
1 Mechanical removal of weld seam - polishing
•Fitthe tube belt grinder assembly onto
theelectric polishing machine
•Usetheceramic grain fabric grinding
belt K80tocompletelysmoothouttheweld
seam
level6
78
Circular tube
•Thetubebeltgrinderassemblyallowseasy
smoothingoutoftheweldseamfrombelow
•Next,useTRIZACT fabric grinding
belts®tomakeapolishablesurface.When
doingthis,workoverlappingoutwardsinto
theundamagedgrindingprofileinturnwiththe
A100andA45belts
level6
Interim result
79
Circular tube
Polishing
•Fitthehard polishing ringontotheelectric
polishingmachine
•Applythe white polishing pasteatlow
polishingring
•Polish"acrossthegrain",i.e.inthefirstwork
step,workagainstthegrindingdirectionofthe
lastworkstepwithA45
•Next,workcrosswaysuntilalltracesofgrinding
havebeenremoved
2,500rpm/level5-6
•Ifnecessary,repeattheprocedurewithblue
buffingpasteandasoftpolishingring
directionatareducedspeedofapprox.1,200
min-1/level2
80
Circular tube
•Finally,removethepolishingpasteresidue
withVienna polishing chalkandmicro
active cloth
Final result
Products
•CeramicgrainfabricgrindingbeltK80,Art. No. 0673 408 008
•FabricgrindingbeltTRIZACT®A100/A45,Art. No. 0673 508 ...
•Hardpolishingring,dia.200mm,Art. No. 0673 03 200
•ClampingmandrelM14forPM200-E,Art. No. 0702 451 020
•Optional:Bluebuffingpaste,Art. No. 0673 05 3
•Optional:Softpolishingring,dia.200mm,Art. No. 0673 04 200
81
Circular tube
Initial situation: Welded-in 90° round elbow
Removing the weld seam on the inside elbow
•Fitthe tube belt grinder assembly onto
theelectric polishing machine
•Usethenarrowceramic grain fabric
grinding belt K80(15mm)tocompletely
smoothouttheweldseams.Recommended
speed:approx.2,500rpm/level6
82
Circular tube
Transition matchings of tube diameter differences
•Duetotheminimaldiameterdifferences
betweenthetubeandweldelbow,itmaystillbe
necessarytomatchthetransitions.
•Thiscanbedonewiththeangle grinder
INOXandsegmented grinding disk OSF
•Important:Asflatacontactangleas
possible,15-30°
3,800rpm/level2-3
Removing the weld seam on the outside elbow
•Thetubebeltgrinderassemblyontheelectric
polishingmachinewithaceramicgrain
grindingbeltK80(35mm)isagainsuitableon
theouterelbow
•Tip:Bringthefixedguidedisksintocontact
withthetubeandguidetheunitataright
angle (90°)alongthetubeinordertocreate
anexactgrindingprofile
level6
TIP FOR PROS:
Bringthefixedguiderollersintocontactwiththesurfaceandmove
withthemachine.Thismakesiteasiertogentlyguidethebeltonthe
tubeandpreventsitfromrunningoutoftrue
83
Circular tube
Interim result
Reducing surface roughness on the outside
•Next,usetheTRIZACT fabric grinding
belt® A100tosignificantlyreducethesurface
roughnessintheouterelbow.Note:Thebelt
isnotsuitablefortheinsideelbow(scoring!)
•Grindslightlyoverlappingintothegrinding
profiletotheleftandrightoftheexisting
workinglocation
level6
84
Circular tube
Reducing surface roughness on the inside and creating a polishable surface
•UsetheINOXanglegrinderandhardpressed compact fleece disk with
fabric platetoinitiallyreducethesurface
roughnessontheinsideface
•Next,createapolishedsurfaceintheentire
workingarea
possible,approx.10–15°
•Important:Guidethemachineslowly
level3
Polishing
•Fitthehard polishing ringontothe
electric polishing machine
polishingring
85
Circular tube
•Duringpolishing,itisalwaysnecessaryto
polish"acrossthegrain",i.e.thepositionof
themachineischangedseveraltimessothat
youarealwaysworkingagainstthepreceding
polishingoperation
•Makesurethatalltracesofgrindingonthe
entireworkinglocationarepolishedout
2,500rpm/level5-6
directionatareducedspeedofapprox.
1,200rpm/level2(notillustrated)
•Ifnecessary,repeattheprocedurewithblue
buffingpasteandasoftpolishingring
•Removethepolishingpasteresiduewith
Vienna polishing chalkandmicro
active cloth
86
Circular tube
Final result
Products
•Hard-pressedcompactfleecediskwithfabricplate,Art. No. 0585 012 348
•TubebeltgrinderassemblyRBS650Art. No. 0673 200
87
Circular tube
Initial situation: Welded-on end piece (cover) on tube
Removing the weld seam from below (tube side)
•Completesmoothingoutoftheweldseam
withtheINOX angle grinderandthe
segmented grinding disk OSF
possible,approx.10–15°
3,800rpm/level2-3
TIP FOR PROS:
Inordertoavoidunevenness,exertpressure
onlyontheweldseam
88
Circular tube
Removing the weld seam from above (cover)
•Changetothehard support plate for
Velcro disks (black)andfabric Velcro
disk TRIZACT® A160
•Removetarnishingandweldseamonthecover
andcreateafinegrindingprofile
•Nowchamfertheedge(deburring)
level3
Interim result
89
Circular tube
•Next,usethehard-pressed compact fleece disk with fabric
platetomakeapolishablesurface.
90
Circular tube
Polishing
•Fitthe hard polishing ring ontothe
polishingring
•Polishoutalltracesofgrindingonthetubeand
cover
2,500rpm/level5-6
•Ifnecessary,buffwithbluebuffingpaste
active cloth
91
Circular tube
Final result
Products
•FabricVelcrodiskTRIZACT®A160,Art. No. 0573 412 012
•Hard-pressedcompactfleecediskwithfabricplate,Art. No. 0585 012 348
•Optional:Softpolishingring,dia.200mm,Art. No. 0673 04 200
92
Circular tube
Initial situation: tube welded onto plate
•Firstmaskoffthebaseplatewithstainless
steel strip
•Usethefillet seam grinderandhardpressed compact fleece disk, hardness
8 (hard), 3 mmtoremovetheweldseam
beadsinordertoproduceasmoothtransition
totheplate
level6
93
Circular tube
•Next,usethehard-pressed compact
fleece disk, hardness 5,
(soft) 6 mmtoreducethesurfaceroughness
level2
Interim result
94
Circular tube
Polishing the tube
•Changetothefelt disk andapplyblue buffing pasteatlow
speed
•Polishtheplatewiththefrontofthefeltdisk
•Recommendedspeed:Startatapprox.2,400rpm/level3.Varythe
speedslightly,dependingontheresult
95
Circular tube
•Next,removethepolishingpasteresidue
active cloth andpulloffthestainlesssteel
strip
Polishing the base plate
•Fitthe soft polishing ring ontotheelectric
polishing machine
speed(900rpm/level1)directlyontothe
polishingring
•Next,polishthebaseplate
2,500rpm/level5-6
•Ifnecessary,buffwithbluebuffingpasteandthe
softpolishingring
•RemovethepolishingpasteresiduewithVienna
polishingchalkandmicroactivecloth
96
Circular tube
Final result
Products
•Feltpolishingdiskdia.150mm,Art. No. 0673 040 150
97
Circular tube
5 Removing saddle seam - polishing
Initial situation: Tubes welded together with saddle seam
Toobtainagoodendresult,theweldseammustalreadyhavebeendrawnverypreciselyifpossible.Whenremovingtheweldseam,ensurelowsurface
roughnessrightfromthestart
•Usethefillet seam grinder andhard-pressed compact fleece disk, hardness 8 (hard), 3 mmtocompletelyremovetheweldseambeads
sothatasmoothtransitionisobtained
•Important:Ensureexactguidanceofthediskontheweldseam,otherwiserecessesthatcannolongerbegroundoutwilloccur
98
Circular tube
Interim result
fleece disk, hardness 5,
(soft) 6 mmtoreducethesurfaceroughness
andremovethetarnishing
level2
Interim result
99
Circular tube
Polishing the weld seam
•Fitthefelt diskandapplyblue buffing
pastedirectlyontothefeltdiskatlowspeed
•Usethefrontofthefeltdisktopolishthe
previouslyworkedsurfacesuntilalltracesof
grindinghavebeencompletelyremoved
100 PRACTICAL MANUAL SURFACE FINISHING RUSTPROOF STAINLESS STEEL
Circular tube
•Finally,removeallpolishingpasteresidue
active cloth
Final result
Products
PRACTICAL MANUAL SURFACE FINISHING RUSTPROOF STAINLESS STEEL 101
Circular tube
6 Removing corner/miter/fillet seam – polishing
Initial situation: Round tubes welded to each other with a miter seam
Removing corner/miter weld seam on the outside
•UsetheINOX angle grinderandsegmented grinding disk
OSFtocompletelysmoothouttheweldseamuptothefinishgrind,and
leaveonlythefilletseam
•Makesurethatnosharpburrremainsontheedge
•Inordertoavoidunevenness,exertpressureonlyontheweldseam
Circular tube
Interim result
•Next,usethehard-pressed compact fleece disk with
fabric platetomakeapolishablesurfaceontheentiresurface
areathathassofarbeenworked
•Important:Asflatacontactangleaspossible,10–15°
Circular tube
Interim result
8 (hard), 3 mmtocompletelyremovethe
weldseambeads
4,000rpm/level5-6
Circular tube
fleece disk, hardness 5 (soft), 6 mmto
reducethesurfaceroughnessandremovethe
tarnishing
level2
Polishing
•Fitthehard polishing ringontothe
polishingring
Circular tube
•Duringpolishing,itisalwaysnecessaryto
polish"acrossthegrain",i.e.thepositionof
themachineischangedseveraltimessothat
youarealwaysworkingagainstthepreceding
polishingoperation
•Makesurethatalltracesofgrindingonthe
entireworkinglocationarepolishedout
•Ifnecessary,applypasteagainbetweenthe
polishingoperations
2,500rpm/level5-6
directionatareducedspeedofapprox.
1,200rpm-1/level2
Circular tube
•RemovethepolishingpasteresiduewithVienna polishing chalkandmicro active cloth
Final result
Circular tube
•Preciselyworked45°miter
Products
•Hard-pressedcompactfleecedisk,hardness5(soft),6mm,Art. No. 0585 915 243
Square tube
Square tube
INDUSTRIAL FINISH
Removing tarnishing
ringtocompletelyremovethetarnishingin
thegrindingdirection(holdmachineparallelto
tube)
•Recommendedspeed:900rpm/level1with
mediumpressure
Square tube
Final result (topside only)
Products
Square tube
Initial situation: Miter-welded tubes
Preparation for removing the tarnishing
•Stickstainless steel stripexactlyalongthe
weldseamsothattheedgeofthestainless
steelstriprunspreciselyinthemiddleofthe
weldseam
•Bendtheedgesofthestripdownwards
Square tube
Removing tarnishing on the miter seam
•Withtheelectric polishing machineand
orange folded grinding fleece ring,
workinthegrindingdirectionofthetubeover
theweldseamandthestainlesssteelstrip
•Recommendedspeed:900rpm/level1with
mediumpressure
•Attention!Payattentiontotherotation
directionofthefoldedringsothatthestainless
steelstripisnotdetached
•Repeattheprocess,i.e.stickthestainlesssteel
adhesivestripontotheothersideandgrind
again
Interim result
Square tube
Removing tarnishing from the corner seam
•Atthefront,thetarnishingisalsoremovedwith
theorangefoldedgrindingfleecering
•Payattentiontotherotationdirectionofthe
foldedgrindingfleecering,otherwiseitwill
weardownquickly
Removing tarnishing from the fillet weld
•Thefillet seam grinderandhardpressed compact fleece disk, hardness
5 (soft), 6 mmcanbeusedtoremovethe
tarnishingdirectlyinthefilletseamandinthe
adjacentarea
Square tube
Finish
•Duetotheslightsurfaceroughness,itisthen
onlynecessarytoreworkslightlywiththe
Schleiffix K60
•Hint:CuttheSchleiffixatanangle
Final result
Products
Square tube
Initial situation: Butt-welded square tube
•Usetheelectric polishing machine,hard
support plate (black)andfabric Velcro
disk (ceramic grain) K120toremovethe
weldseaminthegrindingdirection
•Ensurethatthetoolisguidedcorrectlyalong
theweldseamsothatnorecessesareground
in
Removing traces of grinding
•Changeovertothemedium support plate
(red)withfabric Velcro disk TRIZACT ®
A100andcompletelyremovethetracesof
grinding
level3
•Next,repeatthegrindingprocesswiththe
fabric Velcro disk TRIZACT® A45
overlappingintotheadjacentgrindingprofile.
Whendoingthis,reducethepressuretowards
theoutside
TIP FOR PROS:
Themachinemustbeguidedslowly.Theslowerthe
machineisguided,thelessthesurfaceroughness.
Whendoingthis,payattentiontotheheatgeneration.
Square tube
•Usetheorange folded grinding fleece
ring tomatchthegrindingprofile
•Recommendedspeed:approx.900rpm/level1
•Exertingsomewhatmorepressureinthe
grindingdirection(guidethemachineparallelto
thetube),matchthegrindingprofiletothefinish
grind
Final result
Products
•FabricVelcrodisks,TRIZACT®A100/A45,Art. No. 0573 412 …
Square tube
Initial situation: Square tubes butt-welded into a T shape
Removing outer weld seam
•Usetheelectric polishing machine, hard support plate
(black)andfabric Velcro disk (ceramic grain) K120toremove
theweldseam
•Ensurethatthetoolisguidedcorrectlyalongtheweldseamsothatno
recessesaregroundin
Square tube
Removing traces of grinding across the surface
•Onthepreviouslyworkedpoint,usethemedium support plate (red)andfabric Velcro disk TRIZACT® A100tocompletelyremovethe
tracesofgrinding
Preliminary work for grinding profile matching
1. Working the abutting tube
2. Working the transverse tube
•Usethemediumsupportplate(red)andfabricVelcrodiskTRIZACT®
A100inturntogrindbothtubes.The order of working is
important:
1.Startwiththeabuttingtube
2.Thengrindthetransversetube.Onlyinthiswayisitpossibletocreate
acleanpartitionlinebetweenbothgrindingprofilesasearlyasinthis
workstep
•Next,usethefabric Velcro disk TRIZACT® A45torepeatthe
grindingprocessoverlappingintotheundamagedadjacent
grindingprofileasdescribed
•Speedapprox.1,500rpm/level3
Square tube
Interim result
•Stickstainless steel strip exactlyalongthebutt.Bendthecorners
downslightly
•Usetheelectricpolishingmachineandorange folded grinding
fleece ring withsomewhatgreaterpressureinordertomatchthe
grindingprofileuptothefinishgrind
Square tube
•Coverthelongitudinaltubethathasjustbeen
groundwiththestainlesssteelstrip,andmatch
thetransversetubetothegrindingprofileupto
thefinishgrind,asdescribedabove
Interim result (outer weld seam removed)
Removing the inner seam
8 (hard), 3 mmtoremovetheweldbeads
andcreateasmoothtransition
diskalongtheweldseam,otherwiserecesses
thatcannolongerbegroundoutwilloccur
4,000rpm/level5-6
Square tube
Interim result
Removing tarnishing
disk, hardness 5 (soft), 6 mm,toremove
thetarnishingtotheleftandrightoftheweld
seam
level2
Square tube
Finish
•UseSchleiffixtoagainmatchthegrinding
profileuptothefinishgrindonbothleftand
right
•Hint:FirstcuttheSchleiffixatanangleusing
aknife
Final result
Products
•FabricVelcrodisksTRIZACT®A100/A45,Art. No. 0573 412 …
Square tube
5 Removing corner seam - matching of grinding profile
Initial situation: Corner seam/welded-on cover on square tube
Removing the corner seam
•Removetheweldseamwiththeelectric polishing machine, hard
support plate (black)andfabric Velcro disk (ceramic grain)
K120.
•Whendoingthis,makesureyouobtainarightangleatthecorners
•Toremaininthegrindingdirection,ifpossibleholdthemachineata
90°angletothetubewhenworkingandapplythepressuretothefront
partofthedisk
•Thecontactanglefromtheadhesivesupportplatetotheworkpiece
shouldbe10–15°
•Ensurethatthetoolisguidedcorrectlyalongtheweldseam
Square tube
Reducing surface roughness and removing tarnishings
•Usethemedium support plate (red)and
thefabric Velcro disk TRIZACT® A100to
completelyremovethetracesofgrindingon
thetubesidesandonthecover
level3
•Next,repeatthegrindingprocesswiththe
fabric Velcro disk TRIZACT® A45
overlappingintotheadjacentgrindingprofile.
TIP FOR PROS:
Themachinemustbeguidedslowly.Theslowerthe
machineisguided,thelessthesurfaceroughness.
Whendoingthis,payattentiontotheheatgeneration.
Square tube
Interim result
Chamfering the edges
•BurrsarealsoremovedwiththefabricVelcrodiskTRIZACT®A45onthemediumsupportplate(red)
Square tube
•Replacethepreviouslyusedsupportplatewith
theorange folded grinding fleece ring
and,withcontactpressureandquickmovements
onthesides,matchthegrindingprofilewiththe
coverandedges
•Attention!Payattentiontotherotation
directionoftherollersothatitdoesnothitthe
topedge
Square tube
Final result
Products
•FabricVelcrodisks,TRIZACT®A100/A45,Art. No. 0573 412 …
Square tube
6 Removing corner/miter/fillet seam – matching of grinding profile
Initial situation: Frame welded from square tube
Removing miter weld seam
•Usetheelectric polishing machine,hard
support plate (black)andthe fabric
Velcro disk (ceramic grain) K120to
removetheweldseamacrossthesurface
•Thecontactanglefromtheadhesivesupport
platetotheworkpieceshouldbe10–15°
Square tube
A100onthemedium support plate
(red)toremovethetracesofgrinding
•Important:Alreadyyoumustpayattention
totheoriginalgrindingdirection,i.e.work
theindividualframelegstotheleftandright
ofthemiterinturninthegrindingdirection.
Whendoingthis,payattentiontotherotation
directionofthedisk,i.e.ifpossible,guidethe
machineata90°angletotheframeleg.This
alreadystartstocreatethemiterseam
•Forthefinegrinding,changeovertothefabric
Velcro disk TRIZACT® A45andrepeatthe
procedure.Whendoingthis,grindoverlapping
outwardsintotheundamagedgrindingprofile
inordertocreatesofttransitions
Square tube
Match the grinding profile up to the finish grind
•Maskoffthemiterexactlywithstainless steel strip
•Fittheorange folded grinding fleece ringontotheelectric
polishingmachine
•Withsomewhatstrongerpressureandwithfastmovements,matchthe
grindingprofileinthegrindingdirectionuptothefinishgrind(guidethe
machineparalleltotheframeleg)
•Important:Payattentiontotherotationdirectionofthefoldedgrinding
fleeceringsothatitdoesnotrunagainsttheedgeofthestainlesssteelstrip
• Removethestainlesssteelstripanduseittomaskoffthesurfacethat
hasjustbeenground
•Thenrepeatthegrindingprocedure
Interim result: Miter weld seam removed
Square tube
diskalongtheweldseam,otherwiserecesses
thatcannolongerbegroundoutwilloccur
4,000rpm/level5-6
ADVANTAGE OF
THE FILLET WELD
GRINDER:
Thankstoitslongneck,themachineoffersalternative
holdingpossibilitiesthatallowtheusertohandleit
flexiblyindifferentsituations.
Interim result: Fillet seam removed
Removing tarnishing
•Usea hard-pressed compact fleece disk, hardness 5 (soft),
6 mm,toremovethetarnishingtotheleftandrightoftheweldseam
Square tube
Finish
•UseSchleiffix K60toagainmatchthe
grindingprofileuptothefinishgrindonbothleft
andright
•Hint:FirstcuttheSchleiffixatanangleusinga
knife
Interim result
Square tube
•Removetheweldseamwiththeelectricpolishingmachine,hardsupport
plate(black)andthefabricVelcrodisk(ceramicgrain)K120
•Toremaininthegrindingdirection,themachinemustbeheldata90°
angletothetubeifpossiblewhilethetubeisbeingworkedon
recessesaregroundin
shouldbe10–15°
•Usethemediumsupportplate(red)andthefabricVelcrodiskTRIZACT®
A100tocompletely removethetracesofgrindingonbothsidesof
thetube
•Next,repeatthegrindingprocedurewiththefabricVelcrodisk
TRIZACT®A45overlappingintotheundamagedgrindingprofile
•BurrsarealsoremovedwiththefabricVelcrodiskTRIZACT®A45onthe
mediumsupportplate(red)
Interim result: Corner weld seam removed
Square tube
•Replacethepreviouslyusedsupportplatewiththeorangefolded
grindingfleecering
•Useasomewhatstrongerpressuretomatchthegrindingprofileuptothe
finishgrind
•Attention! Payattentiontotherotationdirectionoftherollersothatit
doesnothittheedge
Final result: Completely smoothed out corner
Products
•FabricVelcrodisks,TRIZACT®,A100/A45,Art. No. 0573 412 …
•FilletseamgrinderKNS150-E,Art. No. 0705 515 0
Square tube
POLISHED SQUARE TUBE
Initial situation: Polished square tubes butt-welded to each other
•Thetarnishingcanbecompletelyremovedwith
theelectric polishing machine,hard
polishing ring andwhite polishing
paste
•Firstapplythewhitepolishingpasteatlow
polishingring
•Removethetarnishingatapprox.2,200–
2,500rpm/level5–6
Square tube
Interim result
Removing the polishing paste residues
active cloth
Final result
Products
•Polishingring,dia.200mm,Art. No. 0673 03 200
Square tube
Chemical-electrical cleaning
•TheWELNOX® cleaning deviceis
particularlysuitableforthechemical-electrical
removaloftarnishing
•Selectandfit the matching feltfromthe
polishing set
•Settherotaryknobto"Polishing"
•Fitthepolishing solutiontothehandpiece
•SwitchontheWElNOx®cleaningdevice
•Soakthepolishingfeltthoroughly
theweldseam
•Donotremaininonespotfortoolong(riskof
burningin)
Square tube
•Removesurpluscleaningsolutionwithadamp
cloth
Final result: Polished weld seam
Products
•PolishingsetICSS300-P,Art. No. 0984 250 902
•Polishingsolution,Art. No. 0893 984 803
•WElNOx®cleaningdeviceICSS300-P,Art. No. 0702 353 550
Square tube
•Removetheweldseamwiththeelectric
polishing machine,hard support plate
(black) and the fabric Velcro disk
(ceramic grain) K120
•Whendoingthis,ensurethatthetoolisguided
correctlyalongtheweldseam
level6
Interim result: Weld seam removed
Square tube
•Completelyremovethetracesofgrindingwith
themedium support plate (red) and
fabric Velcro disk TRIZACT ® A100
level3
•Tip for pros: Themachinemustbeguided
slowly.Theslowerthemachineisguided,the
lessthesurfaceroughness.Whendoingthis,
payattentiontotheheatgeneration.
•Next,endthegrindingprocesswiththefabric
Velcro disk TRIZACT® A45, A30, A16
overlappingacrossthegraintocreatea
polishablesurface
CROSS GRINDING:
Everytimetheabrasivemediumischangedtothenext
finestgrain,changethegrindingdirectionata90°angle
Grinding profile, last grinding operation A16
Square tube
Polishing
• Fit the hard polishing ring ontotheelectric
polishingmachine
•Apply white polishing pasteatlowspeed
(900rpm/level1)directlyontothehard
polishingring
•Duringpolishing,alwayspolish"acrossthe
grain",i.e.inthefirstworkstepagainstthe
grindingdirectionofthelastgrindwithA16
2,500rpm/level5-6
directionatareducedspeed
(approx.1,200rpm/level2)
Square tube
active cloth
Final result
Products
•Whitebuffingpaste,Art. No. 0673 05 1
Square tube
4 Removing weld/fillet seam - polishing
Initial situation: Square tube butt-welded in a T shape
Removing outer weld seam
•Removetheweldseamwiththeelectric
polishing machine,hard support plate
(black) and the fabric Velcro disk
(ceramic grain) K120
level6
•Whendoingthis,ensurethatthetoolisguided
correctlyalongtheweldseam
Interim result: Outer weld seam removed
Square tube
•Onthepreviouslyworkedpoint,usethe
medium support plate (red) for
Velcro disksand the fabric Velcro disk
TRIZACT® A100tocompletelyremovethe
tracesofgrinding
level3
• Tip for pros: Themachinemustbeguided
overlappingoutwardsacrossthegrainintothe
grindingprofiletocreateapolishablesurface
Interim result: Polishable surface
Square tube
Polishing
• Apply white polishing pasteatlowspeed
(900rpm/level1)directlyontothehard
polishing ring
2,500rpm/level5-6
directionatareducedspeedofapprox.1,200
min-1/level2
•Beforethenextstep,removethepolishing
pasteresiduewithVienna polishing chalk
andmicro active cloth
Square tube
andcreateasmoothsurface
• Important: Guidethediskpreciselyalong
theweldseam
4,000rpm/level5-6
disk, hardness 5 (soft) 6 mm, to
weldseam
level2
Square tube
Polishing the fillet seam to a high sheen
•Changetothefelt disk andapplyblue
buffing pasteatlowspeed
•Polishthefilletseamwiththefrontofthefelt
disk
level4
•Guidethemachineoutwards"wiping"inorder
topolishthesurfacetotheleftandrightofthe
weldseam
•UseViennapolishingchalkandmicroactive
clothtoremovethepolishingpasteresidue
Square tube
Final result: Weld seam completely smoothed out and surface restored
Products
•Polishingring,dia.200mm,Art. No. 0673 03 200
Square tube
5 Removing corner/miter/fillet seam – polishing
Removing the miter seam
•Removetheweldseamsintheouterareawiththeelectric polishing
machine,hard support plate (black) andthefabric Velcro
disk (ceramic grain) K120
recessesaregroundin
•Contactangleapprox.10-15°
Interim result: Smoothed out weld seam
Square tube
Reducing the surface roughness over the entire surface
CROSS GRINDING:
Everytimetheabrasivemediumischangedtothenext
finestgrain,changethegrindingdirectionata90°angle
•Onthepreviouslyworkedpoint,usethe
medium support plate (red) for
Velcro disksand the fabric Velcro disk
TRIZACT® A100tocompletely remove the
traces of grinding
level3
• Tip for pros: Themachinemustbeguided
overlappingoutwardsacrossthegrainintothe
grindingprofiletocreateapolishablesurface
Interim result: Polishable surface
Square tube
Polishing
•Applythewhite polishing pasteatlowspeed(900rpm/level1)directlyontothe hard polishing ring
•Duringpolishing,alwayspolish"acrossthegrain",i.e.inthefirstwork
stepagainstthegrindingdirectionofthelastgrindwithA16
Square tube
•Thefinalstepispolishinginthelongitudinaldirectionatareduced
speedofapprox.1,200rpm/level1
•Beforethenextstep,removethepolishingpasteresiduewithVienna
polishing chalkandmicro active cloth.
Interim result: Weld seam removed and polished surface created
•Usethefillet seam grinder andhard-pressed compact fleece
disk, hardness 8 (hard), 3 mm,toremovetheweldbeadsand
createasmoothsurface
•Important: Ensureexactguidanceofthediskalongtheweldseam,
otherwiserecessesthatcannolongerbegroundoutwilloccur
Square tube
disk, hardness 5 (soft) 6 mm, to
weldseam
level2
Polishing the fillet seam to a high sheen
•Changetothefelt disk andapplyblue
buffing pasteatlowspeed(1,300rpm/
level1)
•Polishthefilletseamwiththefrontofthefelt
disk
level4
•Guidethemachineoutwards"wiping"inorder
topolishthesurfacetotheleftandrightofthe
weldseam
Square tube
Interim result: Fillet seam removed and polished on the inside
•Removetheweldseamwiththeelectricpolishingmachine,hardsupport
plate(black)forVelcrodisksandthefabricVelcrodisk(ceramicgrain)
K120
•Toremaininthegrindingdirection,themachinemustbeheldata90°
angletothetubeifpossiblewhilethetubeisbeingworkedon
recessesaregroundin
shouldbe10–15°
Square tube
Interim result: Corner seam removed
Eliminating surface roughness in a problem situation
Situation:Distortedtube/corner(e.g.duetotheweldingprocessoradefectivetube)
•Thetracesofgrindingarenormallyreducedwiththemedium-hard
supportplate(red).However,ifthetubeisnotflatorifthecornersdo
notmeetcleanlyatrightangles,betterresultsareobtainedwiththe
harderblackplatebecausethisguaranteesremovalacrossthesurface
•UsethehardsupportplateforVelcrodisks(black)andthefabricVelcro
diskTRIZACT®A100tocompletelyreducethetracesofgrindingon
bothsidesofthetubeandtosmoothoutanyunevenness
•Next,repeatthegrindingprocedurewiththefabricVelcrodisk
TRIZACT®A45andthemediumsupportplateforVelcrodisks(red)(not
shown)overlappingintotheundamagedgrindingprofile
•BurrsarealsoremovedwiththefabricVelcrodiskTRIZACT®A45onthe
mediumsupportplate(red)forVelcrodisks
Interim result: Corner seam smoothed out
and polishable surface created
Grinding profile from the last work step
Square tube
Polishing
speed(900rpm/level1)directlyontothe
hard polishing ring
•Polishingisthencontinuedacrossthegrain
2,500rpm/level5-6
•Repeattheprocedureonthesecondtube
Square tube
Removing the polishing paste residues
•Removethepolishingpasteresidueonboth
sidesofthetubewithVienna polishing
chalkandmicro active cloth.
Final result
Products
•Whitebuffingpaste,Art. No. 0673 05 1
Cleaning and care
Cleaning and care
1 Removing dirt / slight rust film
Initial situation: Very dirty sheet with slight rust film
•Applymetal cleanersparingly
•Rubthemetalcleanerintothesurfacewitha
textile cloth inthegrindingdirection
Cleaning and care
•Allowittotakeeffectforapprox.10minutes
•Next,removethepastewithatextilecloth
•Thencleanthoroughlywiththemicro active
clothandwater
Final result
Advantages
•MetalcleanerhasNSFapproval(foodstuffsapproval)
•Harmlessingredientssuchascitricacidandaluminaallowanextremelywiderangeofuses
Products
•Metalcleaner,Art. No. 0893 121 1
•Textilecloth,Art. No. 0899 800 901
Cleaning and care
2 Removing slight dirt
Initial situation: Slightly dirty
Cleaning
•Spraythestainless steel power cleaner
ontothedirtysurface,waitashorttimeto
allowittotakeeffectandcleanthoroughly
witha textile cloth
•Ifnecessary,supportthe
cleaningprocesswitha
spongeorbrush
Cleaning and care
Care
•Treatmentwithstainless steel care oil
optimizesthecleaningandcareeffect,thereby
ensuringaperfectsurfacefinish
Final result
Products
•Stainlesssteelpowercleaner,Art. No. 0893 121 205
•Stainlesssteelcareoil,Art. No. 0893 121 0
Cleaning and care
3 Removing slight dirt
Initial situation: slightly dirty metal sheet
• Spray stainlesssteelcaresprayontothedry
surface,polishwitha textile cloth
Final result
Products
•Stainlesssteelcarespray,Art. No. 0893 121
Cleaning and care
4 Cleaning a dirty tube
Initial situation: Dirty tube
• The stainless steel cleaning cloth hastwodifferentsides:
• Thecoarsesideforremovingdepositsanddirt
• Thesoftsideforcleaningandpolishingonly
•Forahighsheenrubwithaclean,drycloth,e.g.textilecloth
Products
•Stainlesssteelcleaningcloth,Art. No. 0893 121 30
Products
Products
ELECTRIC POLISHING MACHINE
PM 200-E
Electric Polishing Machine
Art. No. 0702 453 0
Electric Polishing Machine
Folded Grinding Fleece Rings
Page 173
Support Plates for Velcro Disks
Arbor
Tube Belt Grinder Assembly
Page 174
Page 182
Page 183
Velcro disks
•Fleece
•Fabric
GrindingFleeceRings
PolishingRings
Grinding Belts
•Fleece
•Fabric
Clamping Mandrel
Pages 177-178
FoldedGrindingFleeceRoller
NylonGrindingFleeceRoller
GrindingBladeRollers
BurnishingRollers
GrindingRollers
FineGrindingRoller
Expansion Roller
Inflatable Roller
Drive Roller with bulb
Page 179
Page 180
Page 181
Grinding Sleeves
•Fleece
•Fabric
Grinding Sleeves
•Fleece
•Fabric
Grinding Belts
•Fleece
•Fabric
Products
ANGLE GRINDER
EWS 14-125 INOX Angle Grinder
Art. No. 0702 478 0
Angle Grinder
Segmented Grinding Disks
Page 171
Support Plate
Page 183
Nylon Grinding Fleece Disks
for Velcro Disks
Page 172
Page 174
Cutoff Wheels
GrindingBelts,Fabric
GrindingBelts,Fleece
Fleece
Fabric
Page 172
with cooling fins
Roughing Wheels
Page 175
Page 172
VulcanizedFiber
Disks
Hard-Pressed Compact Fleece Disks
Page 172
Velcro Support Plate
Page 176
FleeceGrinding
Disks
Page 173
Stainless Steel Wire Brushes
Page 173
Products
FILLET WELD GRINDER
KNS150-EFilletWeldGrinder
Art. No. 0702 515 0
Fillet Weld Grinder
Speed plus Cutoff Wheels for stainless steel
Page 172
Page 172
Page 171
Page 172
Blue/green Longlife for steel and stainless steel
Green Longlife for stainless steel
Speed Green for stainless steel
Blue/greenFleeceforsteelandstainlesssteel
FinnedSee-ThroughDisks
One-StepFinishDisk
without cloth plate
with cloth plate
You will find the segmented and cutoff disks that fit onto fillet weld grinders for machining steel in our online catalog at
http://wueko.wuerth.com
Products
dia. 125 mm
Speed Green
for stainless steel
(Surface Professional)
Longlife Green
for stainless steel
(Edge Professional)
Longlife Blue/Green
for steel and stainless
steel
(Edge Professional)
Art. No. 0578 480 524 (K40)
Art. No. 0578 480 526 (K60)
Art. No. 0578 480 528 (K80)
Art. No. 0578 430 324
Art. No. 0578 430 326
Art. No. 0578 430 328
Art. No. 0578 430 321
Fleece Blue/Green for steel
and stainless steel
Finned See-Through
Disks
OSF Disk
(One-Step Finish)
Art. No. 0585 312 510
Art. No. 0585 312 518
Art. No. 0585 312 524
Art. No. 0585 312 540
Art. No. 0578 812 540 (K40)
Art. No. 0578 812 560 (K60)
Art. No. 0578 812 580 (K80)
Art. No. 0585 580 328
Grain: medium
K100(brown)
K180(red-brown)
K280(blue)
K400 (grey)
(K40)
(K60)
(K80)
(K120)
Art. No. 0578 930 324 (K40)
Art. No. 0578 930 326 (K60)
Art. No. 0578 930 328 (K80)
Products
Speed plus Cutoff Wheels for stainless steel
dia. 125 mm
Art. No. 0585 311 5 (dia. 115 mm)
Art. No. 0585 312 5 (dia. 125 mm)
Art. No. 0664 131 248 thickness: 0.8 mm
Longlife Green Roughing Wheels
Speed Blue/Green Roughing Wheels
for stainless steel
for steel/stainless steel
With special multi-layer structure
Art. No. 0670 181 157 (dia. 115 x 7.0 mm)
Art. No. 0670 181 257 (dia. 125 x 7.0 mm)
Art. No. 0664 181 156 (dia. 115 x 6.0 mm)
Art. No. 0664 181 256 (dia. 125 x 6.0 mm)
without cloth plate
dia. 150 mm
Art. No. 0585 012 163
Art. No. 0585 012 173
Art. No. 0585 012 243
Art. No. 0585 012 273
medium hard/fine, 3 mm
hard/medium, 3 mm
soft/very fine, 6 mm
medium-hard/fine, 6 mm
with fabric plate for angle grinder
dia. 125 mm
Art. No. 0585 012 348soft/very fine
Products
Stainless Steel Wire Brushes
Braided
aided Cup Brush
Crimped Cup Brush
Art. No. 0714 692 01 (dia. 65 mm)
Art. No. 0714 692 015 (dia. 60 mm)
Conical Brush
Round Brushes
Art. No. 0714 692 411 (dia. 115 mm)
Art. No. 0714 692 02 (dia. 115 mm)
Art. No. 0714 692 512 (dia. 125 mm)
Dimensions: 125 x 50 mm x M14
extra-coarse/K80 (orange)
Art. No. 0672 911 080
coarse/K100 (red)
Art. No. 0672 911 100
medium/K180 (yellow)
Art. No. 0672 911 180
Products
Support Plates for Velcro Disks
dia. 125 mm
soft (gray)
Art. No. 0585 641 125
medium (red)
Art. No. 0586 642 125
hard (black)
hard(black)
Art. No. 0586 643 125
Velcro Disks (require support plate)
dia. 125 mm
Fleece
medium (yellow)
Art. No. 0585 472 180
Ceramic Grain
TRIZACT®
Art. No. 0573 312 006 (K60)
Art. No. 0573 312 008 (K80)
Art. No. 0573 312 012 (K120)
Art. No. 0573 412 012
Art. No. 0573 412 022
Art. No. 0573 412 028
Art. No. 0573 412 040
Art. No. 0573 412 060
Art. No. 0573 412 120
TRizacT®isaregisteredtrademarkofthe3McompanyintheUS.
(A160)
(A100)
(A65)
(A45)
(A30)
(A16)
Products
Support Plate
dia. 125 mm with cooling fins, connecting thread M14
Art. No. 0586 580 225
Vulcanized Fiber Disks (require support plate)
dia. 125 mm
Normal Corundum
Art. No. 0580 125 16
Art. No. 0580 125 24
Art. No. 0580 125 30
Art. No. 0580 125 36
Art. No. 0580 125 40
Art. No. 0580 125 50
Art. No. 0580 125 60
Art. No. 0580 125 80
Art. No. 0580 125 100
Art. No. 0580 125 120
Zirconium
irconium Corundum
(K16)
(K24)
(K30)
(K36)
(K40)
(K50)
(K60)
(K80)
(K100)
(K120)
Art. No. 0580 512 536
Art. No. 0580 512 540
Art. No. 0580 512 560
Art. No. 0580 512 580
Art. No. 0580 512 512
(K36)
(K40)
(K60)
(K80)
(K120)
Products
Velcro Support Plate with Special Double-Hook Velcro Fabric
M14Thread
Velcro Support Plate with
SpecialDouble-HookVelcroFabric,
with M14 thread
Art. No. 0586 585 125
Fleece Grinding Disks
dia. 125 mm
(extra-strong version)
(soft version)
Art. N0. 0585 470 80 K80/coarse(brown)
Art. No. 0585 470 100 K100/medium(brown)
Art. No. 0585 470 180 K180/fine(brown)
Art. No. 0585 471 80 K80/coarse(brown)
Art. No. 0585 471 100K100/medium(red-brown)
Art. No. 0585 471 280 K280/fine(blue)
Art. No. 0585 471 400 K400/very fine (gray)
Products
Clamping Mandrel
clampingMandrel
Art. No. 0702 451 020
Folded Grinding Fleece Rollers (require clamping mandrel)
Dimensions: 100 x 100 x 19 mm
extra-coarse/K80 (orange)
Art. No. 0672 919 080
coarse/K100 (red)
Art. No. 0672 919 100
fine/K280 (green)
Art. No. 0672 919 280
very fine/K400 (lilac)
Art. No. 0672 919 400
medium/K180 (yellow)
Art. No. 0672 919 180
Grinding Blade Rollers
Nylon Grinding Fleece Roller
(require clamping mandrel)
(requires clamping mandrel)
Art. No. 0672 900 40 (K40)
Art. No. 0672 900 60 (K60)
Art. No. 0672 900 80 (K80)
Art. No. 0672 900 120 (K120)
Art. No. 0672 900 150 (K150)
Art. No. 0672 900 240 (K240)
Art. No. 0672 900 320 (K320)
Art. No. 0585 310 100
Products
Burnishing Rollers (require clamping mandrel)
Grinding Fleece/Linen
Art. No. 0672 910 80 FleeceK100,linenK80
Art. No. 0672 918 150FleeceK180,linenK150
Grinding Fleece
Art. No. 0672 910 0 GrindingFleeceK100
Art. No. 0672 918 0 GrindingFleeceK180
Useit® S/G Metal Grinding Rollers
Fine Grinding Roller
Art. No. 0587 753 600 grinding profile 600
Art. No. 0587 753 150 grinding profile 1500
Art. No. 0672 976 24 (coarse)
Art. No. 0672 976 80 (medium)
Art. No. 0672 976 150 (fine)
Useit® is a registered trademark of Peter Jöst, DE.
Products
Clamping mandrel + Expansion roller
clampingMandrel
Mandrel
Art. No. 0702 451 020
Expansion Roller
ExpansionRoller
Roller
t. No. 0702 460 005
Art.
Grinding Sleeves (require clamping mandrel + expansion roller)
Dimensions: 100 x 100 mm
Fleece
coarse/K100(brown)
Art. No. 0585 551 100
fine/K280(blue)
Art. No. 0585 551 280
medium/K180(red-brown)
Art. No. 0585 551 180
very fine/K400 (gray)
Art. No. 0585 551 400
Zirconium Corundum
TRIZACT®
Art. No. 0672 916 40 (K40)
Art. No. 0672 916 60 (K60)
Art. No. 0672 916 80 (K80)
Art. No. 0672 916 120 (K120)
Ceramic Grain
Art. No. 0672 918 012 (A160)
Art. No. 0672 918 022 (A100)
Art. No. 0672 918 028(A65)
Art. No. 0672 918 040(A45)
Art. No. 0672 918 060 (A30)
Art. No. 0672 917 40 (K40)
Art. No. 0672 917 60 (K60)
Art. No. 0672 917 80 (K80)
Art. No. 0672 917 120 (K120)
Normal Corundum
Useit®-SG
Art. No. 0672 905 40 (K40)
Art. No. 0672 905 60 (K60)
Art. No. 0672 905 80 (K80)
Art. No. 0672 905 120 (K120)
Art. No. 0672 905 150 (K150)
Art.
t. No. 0587 751 600 (grinding profile 600)
Art. No. 0587 751 150 (grinding profile 1500)
Products
Clamping Mandrel + Inflatable Roller
clampingMandrel
Mandrel
Art. No. 0702 451 020
inflatableRoller
t. No. 0702 460 006
Art.
Grinding Sleeves (require clamping mandrel + inflatable roller)
Fleece
coarse/K100(brown)
Art. No. 0585 552 100
fine/K280(blue)
Art. No. 0585 552 280
medium/K180(red-brown)
Art. No. 0585 552 180
very fine/K400 (gray)
Art. No. 0585 552 400
Zirconium Corundum
TRIZACT®
Art. No. 0672 906 40 (K40)
Art. No. 0672 906 60 (K60)
Art. No. 0672 906 80 (K80)
Art. No. 0672 906 120 (K120)
Ceramic Grain
Art. No. 0672 908 012 (A160)
Art. No. 0672 908 022 (A100)
Art. No. 0672 908 028 (A65)
Art. No. 0672 908 040 (A45)
Art. No. 0672 908 060 (A30)
Art. No. 0672 907 40 (K40)
Art. No. 0672 907 60 (K60)
Art. No. 0672 907 80 (K80)
Art. No. 0672 907 120 (K120)
Normal Corundum
Useit®-SG
Art. No. 0672 903 40 (K40)
Art. No. 0672 903 60 (K60)
Art. No. 0672 903 80 (K80)
Art. No. 0672 903 120 (K120)
Art. No. 0672 903 150 (K150)
Art.
t. No. 0587 752 600 (grinding profile 600)
Art. No. 0587 752 150 (grinding profile 1500)
Products
Clamping Mandrel + Drive Roller with Bulb
clampingMandrel
Mandrel
Art. No. 0702 451 020
DriveRollerwithbulb
Art. No. 0702 460 003
Grinding Belts (require clamping mandrel + drive roller with bulb)
White Corundum
Fleece
Art. No. 0672 972 40 (K40)
Art. No. 0672 972 60 (K60)
Art. No. 0672 972 80 (K80)
Art. No. 0672 972 100 (K100)
Art. No. 0672 972 120 (K120)
Art. No. 0672 972 180 (K180)
Art. No. 0672 972 240 (K240)
Art. No. 0672 972 320 (K320)
Art. No. 0672 972 400 (K400)
Art. No. 0585 40 180 (medium)
Products
Arbor M14
arborM14
Art. No. 0702 451 010
Grinding Fleece Rings (require arbor M14)
Art. No. 0673 011 510
2-layer, K100, dia. 150 mm
Art. No. 0673 012 010
Art. No. 0673 011 518
Art. No. 0673 012 018
Art. No. 0673 011 528
Art. No. 0673 012 028
Polishing Rings (require arbor M14)
Sisal Cloth Ring
Hard
Soft
Art. No. 0673 02 150
Art. No. 0673 02 200
Art. No. 0673 03 150
Art. No. 0673 03 200
Art. No. 0673 04 150
Art. No. 0673 04 200
Products
TubeBeltGrinderassemblyRBS650
Art. No. 0673 200
(in case with accessories)
Art. No. 0673 20
(looseinbox)
Grinding Belts (required tube belt grinder assembly RBS 650)
Ceramic Grain
Art. No. 0673 408 004 (K40)
Art. No. 0673 408 006 (K60)
Art. No. 0673 408 008 (K80)
Art. No. 0673 408 012 (K120)
Art. No. 0673 409 008 (K80)
Art. No. 0673 409 012 (K120)
TRIZACT®
Art. No. 0673 508 012
Art. No. 0673 508 022
Art. No. 0673 508 028
Art. No. 0673 508 040
Art. No. 0673 508 060
(A160)
(A100)
(A65)
(A45)
(A30)
Fleece
Art. No. 0673 608 010
K100/coarse(brown)
Art. No. 0673 608 018
K180/medium(red-brown)
Art. No. 0673 608 028
K280/fine(blue)
Art. No. 0673 608 40
K400/very fine (gray)
CUSTOMER SEMINARS
Würth Academy craftmen’s center
Pick up speed with Würth seminars
Thesefast-pacedtimesdemandconstantfurtherlearning,particularlyinourprofessionallives.That'swhyadolfWürth
GmbH&co.KG2004hasdevelopedapractically-orientatedfurthertrainingprogramforcraftsmen.around1,000
seminarsarenowheldatthe45craftsmen'scentersoftheWürthacademy,aswellasdirectlyonourcustomers'
premises.
You can find more information on the Internet at www.wuerth.de.
Seminars specially for stainless steel surface finishing will be available from 2012 onwards.
PRACTICAL MANUAL
SURFACE FINISHING
RUSTPROOF STAINLESS STEEL
adolfWürthGmbH&co.KG
74650Künzelsau,
Germany
Phone: +49 7940 15 - 0
Fax:+49794015-1000
[email protected]
www.wuerth.de
©byadolfWürthGmbH&co.KG
Printed in Germany.
All rights reserved.
Responsibleforcontent:
Dept.PFW/ThorstenKreß
Dept. VSDM/Elke Liehr
Editors: Dept. MWV /Anja Wonner
Reprintinginwholeorinpartisallowedonlywithpermission.
MWc–WaNT–zPPD–50–06/12
We reserve the right to make product changes at any time that we feel provide a quality improvement,
evenwithoutpriorannouncementornotification.
illustrationsmaybeexampleillustrationsthatmaydifferinappearancefromthegoodssupplied.Errors
excepted.Weassumenoliabilityforprintingerrors.
OurGeneralTermsandconditionsapply

PRACTICAL MANUAL SURFACE FINISHING RUSTPROOF

Transcription

Similar documents

kik-step®

ZIMA 126-CS-Fabrication.indd

ISE Spec Sheet-Contractor 333 - InSinkErator

2005 Haulmark This Motorhome is amazing as the pictures will

Your enquiries are always welcome. STAINLESS OUTFITTERS 161

Stainless Steel Kitchen Sinks

bis tristar - LUCKINSlive

Teppanyaki Griddles - Royal Range Of California, Inc.

Barrier-Free Dual Height Wall Mounted Drinking Fountain DF-3701

Chicago Products