Abrasive disc production line for metal cutting

Day by day development is humanity’s continuing to create conveniences for itself. Since the 80s of the last century, when cutting iron or hard objects was a problem, abrasive discs became the solution to this problem. Abrasive cutting discs are mainly produced according to the following body types.

• Wood
• Metal
• Bricks
• Concrete
• Marble-Granite

We will try to explain in detail the necessary raw materials and technologies for the production of metal cutting abrasive discs, which are mainly useful for the customers of AFEX GROUP. Metal cutting abrasive discs are mainly imported from Russia and China. You can reduce the amount of imports by producing this product.

The fact that the production process of this product is not complicated, it is suitable for both new businessmen and experienced entrepreneurs.

REQUIRED PRODUCT INFORMATION.

The photo above shows a disc marked according to state standards for cutting metal. The areas of the disk are marked with numbers, these numbers mean:

1. Constructive type (ISO 41, flat).
2. Geometric characteristics – diameter, thickness, hole.
3. Physical characteristics: abrasive type (A – electrocordum); grain size; degree of hardness (Latin T – very hard); type of connection (BF – reinforced bakelite).
4. Maximum rotation speed.
5. Maximum peripheral speed allowed.
6. For which material it is intended.
7. Security icons.
8. Reference to regulatory documents.
9. Manufacturer’s logo.

The production of the flat type of cutting discs on this line is calculated in the total amount. If you want to produce the depressed type as well, you are required to purchase these product molds.

PRODUCTION PARAMETERS

It uses cutting discs of the necessary sizes for various Bulgarians. We have also selected technologies that produce metal cutting discs that are widely used.

1. Outer diameter: 100,115,125,150,180,230 mm;
2. Diameter of the central ring: 22.32 mm;
3. Thickness: 1.0, 1.2, 1.6, 1.8, 2.0, 2.5, 3.2 mm

RAW MATERIALS REQUIRED

1. Abrasive particles.
2. Resin powder.
3. Cryolite.
4. Gypsum powder.
5. Black carbon.
6. Fiberglass mesh.
7. Special black paper (for the bottom part).
8. Colored aluminum oxide (on the surface).
9. Metal folk.

SALE

In our country, you can find abrasive discs that are mainly imported. The purchase of the product depends on the level of quality. The simplicity of product production increases the possibility of substituting imported products. The fact that the product becomes useless during the cutting process ensures the sustainability of sales.

AREA REQUIRED

The area required for this line should not be less than 150m/sq. If there is an opportunity for light trucks to enter or take out raw materials and finished products, it will increase the productivity.

REQUIRED SUPPLY

Elements of the infrastructure of the industrial facility must be provided with electricity, water supply.

• Line power – 125 KW/380V, 50HZ.

•Required transformer-above 160KW/380V, 50HZ.

• For 1 ton of product – 300 KW energy consumption.

• The number of workers requires 8-10 people.

PRODUCTION MECHANISM

EQUIPMENT AND DEVICES IN THE LINE

•Equipment for cutting glass fiber nets.

•Metal folk making equipment.

•Vibrating sieve.

•Two bowl hydraulic mixer.

•Abrasive disc preparation equipment (100,115,125 mm).

•Abrasive disc preparation equipment (150,180,230 mm).

•Special electric oven.

•Balance checking equipment.

• Testing equipment.

•Air compressor.

We learned about the necessary information about the product and the production mechanism in detail. Now let’s get acquainted with the equipment of the line.

FIBERGLASS CUTTING EQUIPMENT

Fiberglass mesh cutting equipment – with this equipment, you can cut it to the desired size mainly by hand. These meshes serve to strengthen the shape of the abrasive disc. Products cut to size are sent to automatic abrasive disc making equipment.

Cutting equipment (PRESS)
Cutting strength	20T
Desktop size	500*1000 mm
Kroonstein size	350*550mm
Power	1,5kw
Voltage	380v, 3faza
Adjustment range	5-75mm
Hydraulic oil volume	50L
Equipment size	960*950*1600mm
Weight	700kg

METAL RING MAKING EQUIPMENT

Metal ring forming equipment The product made in this equipment acts as a ring that reinforces the center of the abrasive disc. In this equipment, the finished products are also sent to the automatic abrasive disc preparation equipment.

Metal mold making equipment (press)
Nominal pressure	400KN
Stroke speed	45ps/min
Length of vertical columns	340mm
The distance between the center of the liner and the equipment	250mm
Desktop thickness	65mm
Electric motor power	5,5kw%
Weight	3600kg

VIBRATING SIEVE

Using a vibrating screen, we clean the abrasive grains from large or other objects. We send the cleaned abrasive grains to a two-bowl hydraulic mixer.

Vibrating sieve
Model	VS -100A
Amplitude	25-30mm
Vibration frequency	4-5sek
Chewing efficiency	15-20kg/min
Sieve part	1
Sieve size	1080*700mm
Size	1650*650*630mm
Power source	380V 50Hz 3faza
Power	0,55kw
Weight	200 kg

TWO BASIN HYDRAULIC MIXER

We add the necessary components to the abrasive grains in two-bowl hydraulic mixers and mix them well. The prepared raw materials are sent to the automatic abrasive disc preparation equipment.

Two bowl hand mixer
Model	MIX-2-100A
Useful size	120L
Maximum load weight (abrasive)	100kg
Fork lifting and lowering speed	42-48 rpm
The speed of rotation of the cabin up and down	10-40min
Container size	D900mm*T 400mm, thickness 22mm
Installed power	15 kw
Power hungry	4,5-6kw
Power source	380v 50hz 3faz
Each container size	2200*1200*1580
Weight	4200 kg

ABRASIVE DISC PREPARATION EQUIPMENT (100,115,125 mm)

Abrasive disc preparation equipment produces 100, 115, 125 mm abrasive discs in these small sizes. The equipment automatically fills abrasive grains, glass fiber chips, colored aluminum oxide on the surface.

Cutting lisk preparation equipment
Model	PRS-P46T125A45
Production diameter	100,115,125mm
Thickness	1-7mm
Nominal pressure	1250kn
Structure	46 workstations
Management mode	Plc touch screen display
Work rhythm	Grinding time is 6-9 seconds
Air cylinder	SMC
Power	25kw
Power source	380v 50hz 3faz
Weight	5500 kg

ABRASIVE DISC PREPARATION EQUIPMENT (150,180,230 mm)

Abrasive disc making equipment produces 150, 180, 230 mm abrasive discs in these large sizes. The difference between this equipment and the small abrasive disc making equipment is only in the width of the dies. This equipment also automatically fills the surface with abrasive grains, glass fiber chips, and colored aluminum oxide.

Cutting disc preparation equipment
Model	PRS-P42T250A679
Production diameter	150,180,230mm
Thickness	1-7mm
Nominal pressure	2500kn
Structure	42 workstations
Management mode	Plc touch screen display
Work rhythm	Grinding time is 8-12 seconds
Air cylinder	SMC
Power	30kw
Power source	380v 50hz 3faz
Weight	8400 kg

SPECIAL ELECTRIC OVEN

Using a special electric oven, the products made in the abrasive disc preparation equipment are heated at 200C.

Electric oven
Model	OVN-304
Internal capacity	3CBM
High temperature	250C
Operating temperature	180C
Installed power	31,8KW
Consumption power	10-12KW
Power source	380V 50GZ 3FAZ
Weight	150KG

BALANCE CHECKING EQUIPMENT

The product is taken from a special electric oven and checked using the balance checking equipment. We send the tested products to the equipment that checks the maximum rotation speed.

Balance checking equipment
Model	SBT-410S
Test size	100-250mm
The shape of the cutting disc	T41
Accuracy	0,3 g
Electricity supply	380v 50hz 3faz

TEST EQUIPMENT

With the help of testing equipment, you can check the maximum rotation speed of ready-made abrasive discs.

Testing equipment
Model	STM-1636F40
Maximum working speed	36000rpm
Work size	100-400 mm
Hole size	16/22/ 25,4mm
Accessories	Automatic electromagnetic card, printer
Power	5,5kw
Electricity supply	380v 50hz 3faz
Weight	400 kg

AIR COMPRESSOR

The air compressor system is an auxiliary device for the abrasive disc preparation equipment.

Air compressor
Model	AC-BK18-10
Maybe the weather	1CBM
Size	3CBM/min
Power	18kw
Power supply	380v 50 hz 3 faz
Weight	500kg

Video footage of the line’s operation