ALPHA-KUT Quick Change Discs

ALPHA-KUT Quick Change Discs

Introducing our most aggressive coated material

Introduction

As part of our core item offering, Superior Abrasives is a leader in quick change disc production and always looking for innovative additions to our product range. ALPHA-KUT™ is the introduction of our most aggressive coated material available in quick change form. As a potential replacement for some small cutting wheels, coated abrasives, especially in quick change form, are relatively user-friendly and much more forgiving than bonded products. Material can be removed quickly and shaped or smoothed over in one step, reducing tooling changeover for operators. ALPHA-KUT™ allows us to pursue industries like foundries and heavy-duty fabrication while offering a safer, less expensive alternative to some current products used.


What is ALPHA-KUT?

Our new ALPHA-KUT™ product consists of triangular, precision-formed abrasive grains, exhibiting the continually self-sharpening properties and wear characteristics of ceramics for maximum life and consistent cutting action. The triangular grains are applied upright for the sharpest cutting angle, which will reduce heat generation caused by friction. Additional grinding aid is added to prolong the cool-cutting action.

The strength of the manufactured grain is complimented with a rigid, fiber backing, producing stability and added pressure for maximum stock removal. In quick change form no additional liner or backing is necessary, as buttons are securely bonded directly to the fiber.

  • Triangular, precision-formed ceramic grains
  • Consistent, optimum cutting angle
  • Self-sharpening ceramic wear characteristics
  • Stable base with sharp cutting points
  • Immediate, aggressive stock removal
  • Durable, rigid fiber backing
  • Reduced heat buildup with grinding aid

Applications

ALPHA-KUT™ quick change discs can simply be used in the same manner as other coated quick change discs, but would be overkill on anything less than heavy material removal or hardened materials. Primary examples include cast parts in which the sprue is removed, large parts with excessive parting lines, or large weld removal in narrow or otherwise inaccessible areas of larger workpieces.

  • Cast parts shaping or removal, including sprues or parting lines
  • Leveling and rough shaping
  • Large weld or seam removal and blending
  • Heavy material removal

Industries

Primarily, the foundry and fabrication industries are most accepting of aggressive removal products. Hours and even days are spent prepping large cast parts for further machining or final use, so reduced operator effort, or tooling and product changeover can accumulate to several hours of savings every week. In smaller forms of fabrication, ALPHA-KUT™ will be used as an ultra-aggressive coated abrasive producing speed over other products.

  • Foundries and Fabricators using the following:
    • Cast Iron
    • Ductile Iron
    • Stainless Steel
    • Carbon Steel

Performance

You will find that while ALPHA-KUT™ can complement existing coated abrasives, it may be a suitable replacement for small diameter or light-use cutting wheels. The relatively forgiving nature of coated quick change discs allows new and inexperienced operators to perform tasks without much risk to expensive workpieces, and can reduce secondary processes.

While quick change discs do not have the surface area of 4-1/2”+ resin fiber discs, they have the advantage of being controllable in narrow or hard-to-access geometries. ALPHA-KUT™ can also be presented as value-added solutions to the operator.

  • Replacement for light-use cutting wheels
  • Most aggressive coated abrasive
  • More forgiving than cut-off or grinding wheels (bonded abrasives)
  • Medium to high contact pressure

DiameterMax RPMOptimal RPMStd. Pkg.36 Grit
1-1/2″30,00013,00010055841
2″30,00010,50010055842
3″20,0007,0005055843

ALPHA-KUT quick change discs are available in limited sizes and only one grit size.

  • Type R quick change
  • Military-grade nylon button
  • No additional backing liner
  • Available in 1-1/2″,  2″ &  3″ diameter

SHUR-KUT Quick Change Discs


With one of the largest material offerings in our product lineup, coated quick change discs are a workhorse


Some of the versatility of quick change discs comes from the vast offering of materials. While ceramic materials are specialized in application, several other grains also cater to ideal operations. The unique quick change functionality eases transitions between materials to make these discs one of the most agile products in our offering.

Each unique group of abrasive grains share similar qualities tailored toward specific applications and operations. Some factors to consider when choosing abrasive grains are cut rate, finish quality, production environment and cost, as applied to any particular surface or workpiece.

The reduced diameter of quick change discs provide ease of use on intricate parts and excellent control when shaping or blending surface imperfections

  • General purpose grinding and stock removal
  • Deburring or parting line removal on cast parts
  • Spot weld removal and blending
  • Mold and cavity grinding and refurbishing
  • Grinding and preparing hot castings

Ready To Find Your Solution

Contact us for more information, or view our selection of products and solutions.

Surface Conditioning

SHUR-BRITE® Surface Conditioning

A versatile material for a multitude of applications

Characteristics

Like other nonwoven abrasives, SHUR-BRITE® Surface Conditioning consists of fibers, grains and resins, but is more aggressive. The unique characteristic is the integrated woven substrate, or scrim reinforcement, which creates strength and one-sided use, similar to SHUR-KUT® Coated Abrasives. Variations of SHUR-BRITE® Surface Conditioning reinforcement include Standard Scrim, Low Stretch (LS) and Flex (XF).

Features

Surface conditioning materials are considered the workhorse of SHUR-BRITE® Nonwoven Abrasives. Consider the same form and function of coated abrasives, with the added benefits of conformability and forgiveness, reduced loading, and consistent performance. SHUR-BRITE® Surface Conditioning products are not as aggressive as most SHUR-KUT® Coated Abrasives but showcase their versatility between heavy grinding and fine finishing with several material grades available.


  • Consistent finishes throughout product life
  • Lower operational heat than coated abrasives
  • Reduced loading, smearing and discoloration
  • Reduced process stages
  • Suitable for wet or dry applications
  • Conformable cutting action better for off-hand finesse


Applications

  • Mold & die restoration polishing
  • Blending coated abrasive scratch patterns
  • Surface preparation before painting or coating
  • Architectural & aesthetic finishing
  • Blending parting lines on cast parts
  • Stock removal & weld blending
  • Corrosion, rust & oxidation removal
  • Spatter removal & cleanup
  • Removing flash & runners from cast parts
  • Gasket & adhesives removal
  • Paint, scale or surface coating removal
  • Off-hand finishing & cleaning





XE High Performance

Heavy duty action with a unique resin formula. Firm cutting action for aggressive stock removal.





EP Extended Performance

Aggressive cutting action and consistent finishing. Better edge retention for extended life.





GD Grind Duty

Balanced cutting rate and repeatable finishing qualities.





FD Finish Duty

Excellent surface finish control.

Nonwoven Materials

SHUR-BRITE® Nonwoven Abrasives

Understand the basic characteristics of nonwovens

Nonwoven Features

SHUR-BRITE® offers the full range of nonwoven products for solving pre- or post-process applications. From shaping and deburring to cleaning and polishing, the versatile structure of SHUR-BRITE® Nonwoven Abrasives provides flexibility, conformability, strength and consistency. Complimentary to SHUR-KUT® Coated Abrasives, SHUR-BRITE® Nonwoven Abrasives are better able to navigate workpieces without marring or gouging and can enable any final finish requirements.

Nonwoven Characteristics

All SHUR-BRITE® Nonwoven Abrasives consistently feature three components – nylon fibers, abrasive grains and resin. Each component is equally important and cannot perform a proper task without the others. The key to SHUR-BRITE® Nonwoven Abrasives are the nylon fibers, which give products their dimensional, open structure, and control the conformability.

The synthetic fiber structure, or fleece, is impregnated with abrasive grains and resins. The grains attach to the fiber, and the resin bonds these components together, leaving open areas throughout the nonwoven structure. Synthetic nylon fibers are the cushioning foundation which carry the grain media providing the cutting action.

Ready To Find Your Solution?

Contact us for more information, or view our selection of products and solutions.

  • Surface Conditioning

  • Satin Finishing

  • Convolute

  • Unitized

  • Stripping

Applications

  • Directional finishing of stainless steel
  • Mold & die restoration polishing
  • Blending coated abrasive scratch patterns
  • Surface preparation before painting or coating
  • Architectural & aesthetic finishing
  • Mirror finish polishing
  • Blending parting lines on cast parts
  • Edge breaking or corner radiusing
  • Stock removal & weld blending
  • Corrosion, rust & oxidation removal
  • Cleaning & micro-deburring threads or gears
  • Spatter removal & cleanup
  • Removing flash & runners from cast parts
  • Gasket & adhesives removal
  • Paint, scale or surface coating removal
  • Off-hand finishing & cleaning
  • Cleaning & removing weld discoloration
  • Blending & removing tool or handling blemishes

Understanding Ceramic Grains

Understanding Ceramic Grains

Understanding the unique properties of various products and grains can result in productivity gains

What makes ceramic grains unique?

Unlike other synthetically fused abrasive grains, ceramic grains are uniformly produced by a controlled chemical process to provide optimal strength and consistent properties. They are made in a way which creates thousands of fracture points throughout, ensuring consistent breakdown and life.


How do they work?

The characteristic crystalline structure of ceramic grains provides numerous cutting points within each grain. Contact pressure will fracture weakened cutting points and expose fresh grain surfaces, effectively “self-sharpening” during use. Consider traditional aluminum oxide grains which dull and wear down to a rounded profile. This shape is no longer sharp and too blunt to cut effectively, acting more as a spoon than a knife.

  • Thousands of cutting points
  • Consistent fracture rate
  • Continual self-sharpening
Quick Change Product Showcase

Superior Abrasives, LLC. offers three unique types of ceramic quick change discs for harder steels and alloys that are difficult to grind and finish. Variations in grain properties, backing weights and grinding aids ensure a solution to your unique application.


Premium



  • Light operator pressure
  • High temp applications
  • Aggressive cut rate on hard or exotic alloys
  • Higher, prolonged cut rate

Advantage



  • Medium operator pressure
  • Continual exposure of fine, sharp cutting points
  • Top size coat reduces loading, glazing and dulling

GA (Grinding Aid)



  • Additional heat dissipation for high temp grinding
  • Flexible x-weight backing
  • Extended life

Why do I use them?

The continual fracture rate of ceramic grains prolongs consistent performance and maintains sharp cutting points throughout product life, easily penetrating harder materials. The continual sharpening effect avoids dulling and glazing, both of which will cause overheating and premature wear.

Ceramic grains produce high stock removal rates on most materials, but added pressure is necessary for proper use. Softer materials do not provide enough resistance against the grains and will likely glaze. Or, an operator may combat the reduced fracture rate by overapplying pressure, resulting in unnecessary fatigue for both operator and product.


For higher stock removal or controlled finishing, ceramic grains are optimal for hard steels and exotic alloys, commonly found in the following metalworking industries.

  • Aerospace
  • Chemical or Food Processing
  • Industrial Gas Turbines
  • Medical
  • Commercial or Home Appliances
  • Architectural Finishing

How to Choose Ceramic Grains

Proper selection of abrasive grains can realize efficient, and sometime surprising performance

Each of our ceramic quick change discs have unique properties and characteristics. Different materials also have very unique properties. To utilize ceramic products to the fullest, you must first determine if it is truly the best grain for your application. Ceramic grains require pressure to properly breakdown and realize efficiency. Harder metals, such as stainless steels, provide the resistance to fracture ceramic grains properly.


Consider the Variables

Depending on your process and final requirements, several options are available between our three ceramic grains. Take into consideration some of the variable properties and offerings of each ceramic grain.

Quick Change DiscsPREMIUMADVANTAGEGRINDING AID (GA)
Diameter1″ through 4″1″ through 4″1″ through 4″
ButtonType R & SType R & SType R & S
Grit36, 60-12036-12036-120
BackingPolyesterPolyesterPolyester
WeightY-Wt.Y-Wt.X-Wt.
Grain TypeCeramicFine CeramicCeramic
Coating DensityClosedClosedOpen

Ceramic Application Showcase


Speed doesn’t always win the race


When justifying the necessity of ceramic materials, don’t just consider the removal rate. Working with harder materials requires extra attention and the surface outcome is critical in industry applications such as Aerospace or Pharmaceutical.

If you have been using zirconia on stainless, which is generally acceptable, do you require additional finishing to achieve the desired surface requirement? Zirconia is a tough, durable grain excelling in heavy material removal or shaping, but ceramic grains exceed in their finishing qualities and provide more consistent surface finishes (Ra) than zirconia.

If concerned with achieving and maintaining a finish, ceramic grains will perform closer to their initial finish than most other grains due to their continual fracture rate.

MATERIALGritRa NEWRa USED (2 min.)Variance
Ceramic Premium80132.9119.210%
Zirconia GA80116.745.6561%

Consider the Ra values above. After only two minutes of use, the zirconia Ra value has varied over 60%, whereas the ceramic shows only a 10% difference, projecting consistency throughout use.

SHUR-KUT Quick Change Discs


With one of the largest material offerings in our product lineup, coated quick change discs are a workhorse


Some of the versatility of quick change discs comes from the vast offering of materials. While ceramic materials are specialized in application, several other grains also cater to ideal operations. The unique quick change functionality eases transitions between materials to make these discs one of the most agile products in our offering.

Each unique group of abrasive grains share similar qualities tailored toward specific applications and operations. Some factors to consider when choosing abrasive grains are cut rate, finish quality, production environment and cost, as applied to any particular surface or workpiece.

The reduced diameter of quick change discs provide ease of use on intricate parts and excellent control when shaping or blending surface imperfections

  • General purpose grinding and stock removal
  • Deburring or parting line removal on cast parts
  • Spot weld removal and blending
  • Mold and cavity grinding and refurbishing
  • Grinding and preparing hot castings

Ready To Find Your Solution

Contact us for more information, or view our selection of products and solutions.