The way to do all three is to grind faster with one wheel that wears slowly
Simply put, you need a finishing wheel that can hog. Paper mills always have wanted a good roughing/finishing wheel and why not? It would rough and then just ease into finishing. No changing wheels after each phase. No adjusting speeds and feeds often to avoid chatter. No dealing with the time and other problems of belts or a superfinisher. Much better for the operator. Excellent profile and surface. This user-friendly wheel would simplify grinding and save a lot. It would do it all.
The problem, however, is that no wheel has been good enough to do the entire job well. Some mills use a shellac finishing wheel to rough but the removal rate is low. Some use a roughing wheel to finish but have deep grit marks. Many mills change wheels (four changes for a two-wheel machine) but that takes time and can be physically demanding. Mills finishing with belts or a superfinisher can have stubborn leadlines, grit marks or waves. Many operators feel the quality of a wheel finish is best.
NEWS FLASH - Pacer has designed one wheel that does it all
Pacer has made roll grinding wheels for over 250 North American and overseas paper mills. These are the popular PM roughing and Cork finishing wheels. They rough or finish great but generally are not intended to do both. Paper mills need a wheel that does both. There would be many advantages and cost savings. Pacer now has the special wheel you need. It is the C100I11PM2.
Because this 100-grit wheel roughs and finishes, no time or effort is wasted changing wheels or going to belts. Various 100-grit shellac wheels have been around for years. This is not a shellac wheel. It is new and different. It grinds fast, finishes great and lasts long. Some mills have switched to belts or superfinishers because of chatter or other ongoing wheel problems. Many have found, however, that the switch has not been totally successful. Those methods have their own cost and quality problems, some serious. If one grinding wheel can rough and finish well, that is the way to go. It is more natural grinding. There would be little need to bother with add-on machinery and abrasives.
This is a 100 grit wheel that thinks it is a 60 (or even 46) grit wheel
It thinks so because it cuts so well. The grit is smaller but there are many, many more of them. A good 100-grit wheel should be aggressive and smooth. Easy to say but not easy to design. The grit has to adhere extra well. The structure has to be extra open for resilience. The bond has to be extra tough. The C100I11PM2 has all these extra features. Our grit coating process is new and very adhesive. Our 11 structure is new and very open. Our patented PM resin bond has high strength but “give”. That and the open structure stops chatter. This is one easy, 2 to 4” wide, cost saving wheel.
The C100I11PM2 roughs fast because it is sharp and aggressive. It semi-finishes fast because of the already good surface after roughing. It finishes fast because of no chatter. Long life means rock-bottom abrasive cost, especially compared to belts. You can expect a 4 to 6 Ra and a bright, reflective roll. Operators can expect not to change wheels. This wheel does it all. We guarantee it.
Now is a good time to rethink grinding methods
The job may seem to get done ok now. Your present method likely is the result of many past efforts and may seem to be as good as it gets. Another method, however, might be better - a lot better. It could generate significant savings, higher quality and be easier on the operator. That is worth taking some time to compare your method to this one. Such savings and improvements are not easy to find.
Comparing the present (old) method to the new method
The best way to consider cost savings is to compare the cu” per hr chilled-iron removal rate, wheel changing time, etc. to see how the methods match up. Following are grinding steps and an example:
Example - Assume a present roughing rate of 12 cu”/hr and a total needed removal of 100 cu” and a two-wheel Farrel and a change of wheels. The comparison to Pacer’s C100I11PM2 would be:
The results show a 33% time saving. Multiply that by the rolls per year, and you will see a big number - too big to ignore. There also is the 33% abrasive saving to consider. The C100I11PM2 has longer than normal life. Its infeed rate can be set 1/3 lower than for shellac but still remove the same material; thus, two would last as long as three shellac wheels. The abrasives cost per roll for belts is much higher than for this wheel (which is about $70 per big roll). Worn-out belt cost could be several hundred dollars per roll – plus more time and less quality. You now have a better way to do the job.
Call, fax or e-mail now to order a guaranteed trial wheel — and start saving soon!