02 fers resins for abrasives fsac05 to cd version

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 PHENOLIC RESINS FOR ABRASIVES MANUFACTURING

Toni OllerBU Technical Resins DirectorFERS Resins S.A.U. (Sumitomo Bakelite Group)


Programm: 15 Technical Papers

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FERS Resins - M i l e s t o n e s

1944 1949 1953 1960 1977 1996 1999 2000 2003 2004

Sumitomo Bakelite GroupISO9001:2000

ISO14001:1996

100%Change to New Plant Montornès50th Anniversary

ISO9002:1994New Land in Montornés

Beginning Export SalesYears of Consolidation

Foundation by Oller Brothers.

Brothers Joaquim and Eugenio Oller started trials with phenolic resins

2005


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European manufacturing & Sales network Phenolic Resins

Production (Resin) : 2 countries

FERS RESINS(Montornés – Spain)ISO9001/2000ISO14001/1996

SUMITOMO BAKELITE EUROPE(Belgium – Genk)ISO9001/2000ISO14001/1996

Durez division

SUMITOMO BAKELITE Europe n.v. DUREZ Div. Genk Belgium


EuropeEurope

FERS RESINS

SUMITOMO BAKELITE EUROPE

JapanJapan

SB

IndonesiaIndonesia

IPJ

DUREZ CANADA

DUREZ CORPU.S.AU.S.A

CanadaCanada

Production (Resin): 6 countries

Global manufacturing & Sales network Phenolic Resins


INDUSTRIAL APPLICATIONS

•BONDED ( Cut-off and Grinding Wheels,Stones, Segments... )

•COATED ( Flexible, semi-Flexible)

ABRASIVES MATERIALS


- GRINDING WHEELS

- CUTT-OFF & DEPRESSED CENTER WHEELS

TYPE OF BOND:

VITRIFIED (Ceramic))

RESINOID

RUBBER

METALLIC (Superabrasives)

BONDED ABRASIVES


BONDED ABRASIVESTypical Formulation ( in weight )

ABRASIVE ABRASIVE 76

BONDS POWDER RESIN 12 Usual Ration LR/PR is 1:4 to 1:2

LIQUID RESIN 4

FLUORITE, ... 5 Relation PR + Filler / LR from 3.5 to 7

PYROX, ... 3


BONDED ABRASIVES

PF Bond formulation: Typical resin characteristics and ranges:PF Powder Novolac

Typ.Parameter Typical ranges

Flow, mm Short: 12-20 / Medium: 21-35 / Large: 35-70

Hexamine, % Low: 4-6 / Medium: 7-9 / High: 10-14

Sm (cm2/gr) Low: 4000-5000 / Medium: 5000-7000 / High: 7000-9000

PF Liquid resin


Solid Cont. % Low: 65-70 / Medium: 70-75 / High: 75-80

Viscosity, cps Low: 300-1000 / Medium: 1000-2000 / HIgh: 2000-4000

Free Phenol Low: <2 / Medium: 2-10 / High: 10-20


PowderPowderResinResin typetype

FlowFlow

BONDED ABRASIVES: RESIN GRADE SELECTION FACTORS

ParticleParticlesizesize

CuringCuringTimeTime

OthersOthers

MwMw

LiquidLiquidResinResin typetype

GelGel timetime

ViscosityViscosity

FreeFreePhenolPhenol

SolventSolventtypetype

OthersOthers

PowderPowderResinResin typetype


0

1

2

3APPLICATION

MANUF.PROCESSENVIRONMENTRESIN GRADE

BONDED ABRASIVES: RESIN GRADE SELECTION FACTORS


GRINDING WHEEL MANUFACTURE:

1. Mixing

2. Moulding

3. Curing (Oven or Kiln)

4. Finishing

5. Testing

BONDED ABRASIVES

Abrasive

Liq Res

Bond:

Res Pol +Filler

Mixing

Moulding

Curing

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

BONDED ABRASIVESMANUFACTURING PROCESS


MATERIALS MACHINES ENVIRONMENT

Non Fe Metals & Alloys

Non-PrecisionMachines

EnvironmentRegulations

Fe Metals & Foundry

Precision Machines Safety Regulations

Stainless Steel Variety of BondedAbrasives

Market Behavior

Ceramic & Stone

BONDED ABRASIVES: RESIN GRADE SELECTION FACTORS APPLICATION


012345

Non-FeMetals+Alloys

Steel+Cast Iron

Stainless Steel

Ceramics

Tens.StrengthImpactHeat

BONDED ABRASIVES: RESIN GRADE SELECTION FACTORS APPLICATION / GUIDELINES FOR BONDED ABRASIVES VS MATERIALS

BEHAVIOR

BONDED ABRASIVES


BONDED ABRASIVES


TYPE OF RESINOID ABRASIVE / APPLICATION NON-

PRECISION MACHINES

REMARKS RESIN CRITERIA

ROUGH SNAGGING-SNAGGING HIGH REMOVAL. HIGH PRESSURETHOUGHNESS. HIGH HARDNESS. REINFORCED

(COLD PRESSING) 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

(HOT PRESSING) SNAGGERS AND SEVERE ROUGH GRINDING IN STEEL MILLS AND FOUNDRIES.

POWDER RESIN: SHORT FLOW. HIGH HEXA.EX: FB8023, F1021P /WETTING AGENT: STAB/AF (FURF.ALC.)

CUTTING OFF WHEELS(COLD PRESSING)

HIGH PRESSURE. THOUGNESS AND HARDNESS. REINFORCED. EX: THIN WHEELS.

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


BONDED ABRASIVES


TYPE OF RESINOID ABRASIVE / APPLICATION

PRECISION MACHINES

REMARKS RESIN CRITERIA

EXTERNAL GRINDING FINE ABRASIVE GRIT. MEDIUM DENSITIES. COOLANT RESISTANCE.

POWDER RESIN: FLOW MEDIUM-LONG. HEXA MEDIUM/LOW. OPTION EPOXY MOD, PVB MOD.EX: FB8001, FBF1006P, F910, FB8709LIQUID RESIN: ALCALI FREE. EX: F504B, F501

EXTERNAL GRINDING LARGE DIAMETERS “ROLL

GRINDING”.

FINE ABRASIVE GRIT. MEDIUM-LOW DENSITIES. COOLANT RESISTANCE

POWDER RESIN:FLOW LARGE. HEXA MEDIUM-LOW. OPTION RUBBER MOD, EPOXY MOD.EX: FB8001, F1400P, F910 LIQUID RESIN: ALCALI FREE. EX: F504B, F501

CENTERLESS GRINDING SNAGGERS AND SEVERE ROUGH GRINDING IN STEEL MILLS AND FOUNDRIES.

POWDER RESIN:FLOW MEDIUM-LARGE. HEXA MEDIUM. OPTION EPOXI AND RUBBER MOD. EX: FB8001, F910, F1400PLIQUID RESIN: ALCALI FREE.EX: F504B, F501

SURFACE GRINDING FACE CYLINDER / NUT INSERTED DISC WHEELS. SEGMENTS. FINE/MEDIUM SIZE ABRASIVE GRIT. MEDIUM/LOW DENSITIES. COOLANT RESISTANCE.

POWDER RESIN: FLOW MEDIUM-LARGE.. HEXA LOW. EX: FB8018, F1006P.LIQUID RESIN: ALCALI FREE.EX: F504B, F501

BONDED SUPERABRASIVESDIAMONT WHEELS

APPLICATIONS IN GLASS, CERAMIC AND STONE.

POWDER RESIN: FLOW SHORT, HIGH HEXA.EX: FB8023, F1021PWETTING AGENT: STAB/AF.


POWDERED RESINSFERS Code

General purpose Wheels

High Density Wheels

Hot pressed Wheels

ThoughWheels

Coolant resistant Wheels

Diamond Wheels

Unmodified

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

F1006P X

F1009P X

F1010P X

F1012P X

F1021P

F1026P X

F1050P X

FB8001 X

FB8001/2 X

FB8018

FB8020

FB8023

FB8050 X

FB8107 X

FB8108 X

FB8309 X




High Density Wheels

Hot pressed Wheels

ThoughWheels

Coolant resistant Wheels

Diamond Wheels

Modified

F910 (epoxy) X X

F1420P (rubber) X X

F9003 (epoxy) X X X

F9105 (epoxy) X X

FB4504 (Chromite) X

X

X

X

X

XX

F1400P (rubber)

FB8709 (PVB)


LIQUID RESINS REMARKS SUGGESTED APPLICATIONS

RESIN GRADES

Snagging and General Purpose dry grinding.

F508, F511, F512, F514

F504B, F501, F504, F506K

F5250L, F5251L, F5252L

Coolant resistant wheels,Cutting-Off and DC

wheels, General purpose for free and wet grinding.

Snagging and General purpose dry and wet

grinding.

Alkali liquid resins

PF Resols water based (solvent free) , High-Medium Free Phenol%, Good wetting properties

and high digestion for powder resins.

Alcali Free liquid resins

PF Resols water or solved based, Low-Medium Free Phenol%, Storage stable mixes for

authomatic presses,

SN liquid resin PF Novolacs solved based with low free monomers (Phenol and Formaldehyde). Storage

stable mixes. Long shelf life resins.

Temperature - Viscosity Graph

01.0002.0003.0004.0005.0006.0007.000

µ 15°C µ 20°C µ 25°C µ 30°C µ 35° µ 40°C

Temperature ºC

Visc

osity

cps

F501

F512

F520

LIQUID RESINSFERS Code

Shelf life at 20ºC

Shelf life at 10ºC

F501 2 6

3F504B 1


LIQUID RESINS EFFECTS ON DIFFERENT SOLVENTS

FREE PHENOL -Dissolves Novolac, Hexa and Resol.-Effective Wetting agent. -Less reactive than FA at low temperature.

FURFURYL ALCOHOL

-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.

WATER -Does not dissolve Novolac, but hexa and behavior with resole depends on the water- tolerance.

-Gives relatively high viscosity at low temperatures (<70ºC).-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).


BONDED ABRASIVESENVIRONMENT FACTORS

Environment Regulations

Market Behavior Safety Regulations


INDUSTRIAL APPLICATIONS

•BONDED ( Cut-off and Grinding Wheels,Stones, Segments... )

•COATED ( Flexible, semi-Flexible)

ABRASIVES MATERIALS


Cutting Print 1st Layer ( Maker ) Resin + Abrasive

(number of passes & speed, to be adjusted to the desired product weight)

2nd Layer ( Sizer ) Resin Drying Oven aprx. 2 h at 80 ºC

Packing & Form Curing Oven 70 – 130 ºC ; 24 to 48 h

Humidification Chamber ( 65 – 75 % HR )

Flexing Packaging

ABRASIVES MATERIALSA basic approach to the Fiber discs Manufacture Process0,8 & 2 mm Vulcanized Fiber thickness



Solid Cont. % Low: 65-70 / Medium: 70-75 / High: 75-80

Gel Time 100ºC 50 – 70 min

Viscosity 25ºc, cps Medium: 1500 / HIgh: 3000

Free Phenol % Low <3 / Medium 8

PF Liquid resin

ABRASIVE ABRASIVE REMARKS

BACKING

BOND LAYER

FIBER BACKING 0,6 up to 2,3 mm

LIQUID RESIN 60-70% FERS RESIN GRADES: TH5, TH14.Additional solvent up to 0,5% to adjust viscosity.

FILLERS 30-40% Cryolite, CaCO3, etc

COATED ABRASIVES: FIBER DISCS


“Maker” 1st Bond layer “Coating” ( abrasive layer ) Drying (65-70ºC) “Sizer” 2nd Bond layer Drying-Curing (115-125ºC) Conditioning “Jumbos” (Controlled Moisture & temp storage) Finishings ( Belts, sheets, discs.., Flexing...)

ABRASIVES MATERIALSA basic approach to the Roll Coating Manufacture Process


COATED ABRASIVES: BELTS AND SHEETS

ABRASIVE ABRASIVE

BACKING

BOND LAYER1) “MAKER”2) “SIZER”

FIBER BACKING Usual materials: special Kraft papers, woven cotton, etcBacking material available up to 2 m wide.

LIQUID RESIN 50-60% FERS RESIN GRADES: TH250, TH3478/2, TH751/500, TH751M, DUREZ33104.Additional solvent up to 0,5% to adjust viscosity.

FILLERS 40-50% Cryolite, CaCO3, Others.

PF Liquid resin


Solid Cont. % 70 / 80

Viscosity 25ºc, cps Maker: 1500-3500 / Sizer: 500-2500

Free Phenol Low 3 / Medium 8




Flexibility Water resistant

Modified

TH215 X

TH252/500

DUREZ33104 X

TH751/500 X X

TH3478/2 X

XXTH751BM

COATED ABRASIVES: BELTS AND SHEETS

Resin Targets:

-To reduce free monomers (P, F)

-To stabilize colour.


Our Technical Challenges:

To support our Customers offering resins:

More reliable with the Environment

Better Performance

Easy Processability

Available for any Process

At reasonable Cost



FERS RESINS : YOUR PF RESIN’S PARTNER FOR THE ABRASIVES MARKET

ISO14001

ISO9001

02 fers resins for abrasives fsac05 to cd version

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