Page 25 - MetalForming July 2019

Another: die grinders for small spaces and with smaller-diameter prod- ucts or products with stems attached. Die grinders can be electric, though most are pneumatic. When the setup cannot accommodate the footprint of a right-angle or die grinder, there’s the inline grinder. With this option, the wheel is perpendicular to the straight end of the tool, unlike a right-angle- grinder wheel, which is located to a right angle from the tool itself.
Factors Affecting Tool Power
Several factors affect tool power, performance and safety:
• Amperage. A tool’s amperage keeps the motor spinning consistently at the same speed. When a tool has low amps and an operator applies pressure on the abrasive, the tool will not sustain consistent RPM. With higher-amperage tools, operators maintain power with- out overheating the motor, increasing motor life and abrasive effectiveness.
• Grains. The abrasive’s grains also affect tool power. For example, an oper- ator would need a higher-amperage tool to maximize the efficiency of the grains on a ceramic cutting or grinding wheel. The wheel would need to spin at higher RPMs to fracture the ceramic grains and enable self-sharpening and continual high performance. If a low- amperage tool isn’t getting the job done with a ceramic or zirconia-alumina wheel, an aluminum-oxide wheel requiring less torque may be better. It often makes more sense, economically, to replace the abrasive rather than upgrade the tool.
• Cutting/grinding angle. An increased angle increases the material removal rate when grinding, but it also can cause the operator to put more pres- sure onto the abrasive itself. More pres- sure adds more heat and the possibility of the tool bogging down.
• Extension cord quality. Using an inexpensive or low-quality extension cord affects tool power. For example, a heavy-duty, 12-gauge extension cord allows for grinding with full RPMs while being farther from the power source than a common store-bought 16-gauge
cord. Also, a thinner extension cord may allow the tool to run at free speed and at its rated RPM, but it will likely stall out once the operator adds any kind of load to it.
• Air-compressor quality. Operators should consider how their air com- pressors rate when compared to the number of export air hoses needed when using pneumatic die grinders. If there are multiple cells using air tools,
multiple air compressors or higher quality compressors may be required to feed those cells. The cell farthest away from the air compressor may have the lowest air pressure.
Tool Power Affects Abrasive Performance
Ceramic, zirconia and aluminum- oxide cutting and grinding wheels do the same job but have varying lifespans
Fabrication: Grinding
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