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Toni Oller BU Technical Resins Director FERS Resins S.A.U. (Sumitomo Bakelite Group)
F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005
FERS Resins - M i l e s t o n e s
Sumitomo Bakelite Group ISO9001:2000 ISO14001:1996 2000 2003 2004 2005
Programm:
1944 1949 1953
15 Technical Papers
1960 1977 1996 1999
100%Change to New Plant Montorns 50th Anniversary ISO9002:1994 New Land in Montorns Beginning Export Sales Years of Consolidation Foundation by Oller Brothers. Brothers Joaquim and Eugenio Oller started trials with phenolic resins
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F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005
Indonesia
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F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005
ABRASIVES MATERIALS
INDUSTRIAL APPLICATIONS
F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005
BONDED ABRASIVES
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BONDED ABRASIVES
Typical Formulation ( in weight )
ABRASIVE ABRASIVE 76
BONDS
POWDER RESIN
12
LIQUID RESIN
FLUORITE, ...
PYROX, ...
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BONDED ABRASIVES
PF Bond formulation: Typical resin characteristics and ranges:
PF Powder Novolac Typ.Parameter Flow, mm Hexamine, % Sm (cm2/gr) Typical ranges Short: 12-20 / Medium: 21-35 / Large: 35-70 Low: 4-6 / Medium: 7-9 / High: 10-14 Low: 4000-5000 / Medium: 5000-7000 / High: 7000-9000
PF Liquid resin Typ.Parameter Typical ranges Solid Cont. % Viscosity, cps Free Phenol Low: 65-70 / Medium: 70-75 / High: 75-80 Low: 300-1000 / Medium: 1000-2000 / HIgh: 2000-4000 Low: <2 / Medium: 2-10 / High: 10-20
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Flow
Particle size
Gel time
Curing Time
Viscosity
Others
Others
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APPLICATION
3 2 1 0
ENVIRONMENT
RESIN GRADE
MANUF.PROCESS
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BONDED ABRASIVES
MANUFACTURING PROCESS
GRINDING WHEEL MANUFACTURE: 1. Mixing 2. Moulding 3. Curing (Oven or Kiln) 4. Finishing 5. Testing
Mixing
Moulding
Curing
F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005
BONDED ABRASIVES
MANUFACTURING PROCESS
Processing variables
Mixing / Different technologies / Mixing room conditions Pressing / Different technologies and Systems / room conditions Curing / Standard and Fast Curing Cycles / Oven technology. Final Properties / Aging , Optimizing Performance, etc
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MATERIALS Non Fe Metals & Alloys Fe Metals & Foundry Stainless Steel Ceramic & Stone
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Ceramics
Steel+Cast Iron
Stainless Steel
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BONDED ABRASIVES
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REMARKS
RESIN CRITERIA
HIGH REMOVAL. HIGH PRESSURE THOUGHNESS. HIGH HARDNESS. REINFORCED GENERAL PURPOSE GRINDING WHEELS AND DEPRESSED CENTER WHEELS (#27). POWDER RESIN: FLOW MEDIUM/SHORT. HEXA MEDIUM/HIGH. OPTION EPOXY MOD. EX: FB8107, FB8001, FB8001/2, F910 LIQUID RESIN: STANDARD GRADES. EX: F508, F511, F504B POWDER RESIN: SHORT FLOW. HIGH HEXA. EX: FB8023, F1021P / WETTING AGENT: STAB/AF (FURF.ALC.) POWDER RESINS: FLOW MEDIUM/SHORT. HEXA MEDIUM. OPTION EPOXI AND PVB MOD. EX: FB8001/2, F1021P, F910, FB8709 LIQUID RESIN: ALCALI FREE (LR) F504B, F504
(COLD PRESSING)
(HOT PRESSING)
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BONDED ABRASIVES
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REMARKS
RESIN CRITERIA
POWDER RESIN: FLOW MEDIUM-LONG. HEXA MEDIUM/LOW. OPTION EPOXY MOD, PVB MOD. EX: FB8001, FBF1006P, F910, FB8709 LIQUID RESIN: ALCALI FREE. EX: F504B, F501 POWDER RESIN: FLOW LARGE. HEXA MEDIUM-LOW. OPTION RUBBER MOD, EPOXY MOD. EX: FB8001, F1400P, F910 LIQUID RESIN: ALCALI FREE. EX: F504B, F501 POWDER RESIN: FLOW MEDIUM-LARGE. HEXA MEDIUM. OPTION EPOXI AND RUBBER MOD. EX: FB8001, F910, F1400P LIQUID RESIN: ALCALI FREE. EX: F504B, F501 POWDER RESIN: FLOW MEDIUM-LARGE.. HEXA LOW. EX: FB8018, F1006P. LIQUID RESIN: ALCALI FREE. EX: F504B, F501 POWDER RESIN: FLOW SHORT, HIGH HEXA. EX: FB8023, F1021P WETTING AGENT: STAB/AF.
CENTERLESS GRINDING
CYLINDER / NUT INSERTED DISC WHEELS. SEGMENTS. FINE/MEDIUM SIZE ABRASIVE GRIT. MEDIUM/LOW DENSITIES. COOLANT RESISTANCE.
F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005
POWDERED RESINS FERS Code Unmodified F1006P F1009P F1010P F1012P F1021P F1026P F1050P FB8001 FB8001/2 FB8018 FB8020 FB8023 FB8050 FB8107 FB8108 FB8309
Though Wheels
Diamond Wheels
X X X X X X X X X X X X X
X X X X
X X X X
X X X X X X
X X
X X
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Though Wheels
Diamond Wheels
X X X X X X X X
X X X X X X X X
F9003 (epoxy) F9105 (epoxy) F1400P (rubber) F1420P (rubber) FB8709 (PVB) FB4504 (Chromite)
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REMARKS PF Resols water based (solvent free) , HighMedium Free Phenol%, Good wetting properties and high digestion for powder resins. PF Resols water or solved based, Low-Medium Free Phenol%, Storage stable mixes for authomatic presses, PF Novolacs solved based with low free monomers (Phenol and Formaldehyde). Storage stable mixes. Long shelf life resins.
SUGGESTED APPLICATIONS Snagging and General Purpose dry grinding. Coolant resistant wheels, Cutting-Off and DC wheels, General purpose for free and wet grinding. Snagging and General purpose dry and wet grinding.
RESIN GRADES F508, F511, F512, F514 F504B, F501, F504, F506K
SN liquid resin
Temperature - Viscosity Graph 7.000 Viscosity cps 6.000 5.000 4.000 3.000 2.000 1.000 0 15C 20C 25C 30C Temperature C 35 40C
F501 F512 F520
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LIQUID RESINS
FREE PHENOL
-Dissolves Novolac, Hexa and Resol. -Effective Wetting agent. -Less reactive than FA at low temperature. -Dissolves slowly Novolac due to difficulties to penetrate particles. -Longer time is needed before mix is useful. -Gives additional flow at low temperature. -Gives longer stability to the mixture. -Does not dissolve Novolac, but hexa and behavior with resole depends on the water- tolerance. -Gives relatively high viscosity at low temperatures (<70C). -Non-reactive, no function for final wheel. -Helps penetration of Resol to the Novolac particles, and mixture can be used shortly. -Mixture is sensitive to room climate (moisture).
FURFURYL ALCOHOL
WATER
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BONDED ABRASIVES
ENVIRONMENT FACTORS
Environment Regulations
Market Behavior
Safety Regulations
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ABRASIVES MATERIALS
INDUSTRIAL APPLICATIONS
F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005
ABRASIVES MATERIALS A basic approach to the Fiber discs Manufacture Process 0,8 & 2 mm Vulcanized Fiber thickness Cutting Print 1st Layer ( Maker ) Resin + Abrasive
(number of passes & speed, to be adjusted to the desired product weight) 2nd Layer ( Sizer ) Resin Packing & Form Drying Oven aprx. 2 h at 80 C
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BACKING
FIBER BACKING
0,6 up to 2,3 mm
BOND LAYER
LIQUID RESIN
60-70%
FERS RESIN GRADES: TH5, TH14. Additional solvent up to 0,5% to adjust viscosity.
FILLERS
30-40%
PF Liquid resin Typ.Parameter Solid Cont. % Viscosity 25c, cps Gel Time 100C Free Phenol % Typical ranges Low: 65-70 / Medium: 70-75 / High: 75-80 Medium: 1500 / HIgh: 3000 50 70 min Low <3 / Medium 8
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ABRASIVES MATERIALS A basic approach to the Roll Coating Manufacture Process Maker 1 Bond layer Coating ( abrasive layer ) Drying (65nd 70C) Sizer 2 Bond layer Drying-Curing (115-125C) Conditioning Jumbos (Controlled Moisture & temp storage) Finishings ( Belts, sheets, discs.., Flexing...)
st
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FILLERS
40-50%
PF Liquid resin Typ.Parameter Solid Cont. % Viscosity 25c, cps Free Phenol Typical ranges 70 / 80 Maker: 1500-3500 / Sizer: 500-2500 Low 3 / Medium 8
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Resin Targets: -To reduce free monomers (P, F) -To stabilize colour.
F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005
More reliable with the Environment Better Performance Easy Processability Available for any Process At reasonable Cost
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ISO14001
ISO9001
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