• The web design allows a controlled contact between the products and the work piece. If follows the contours, edges, and corners to help avoid undercutting or generating flat areas.
• The open web provides ventilation that helps dissipate heat and therefore, runs cooler. Helps avoid warping, burning or discoloration.
• Because all the elements are non-metallic, there's no danger from loose flying wires-and operation is far quieter than wire brushes or grinding wheels. Metal contamination of the surface is eliminated.
• The Valgro-Fynex products slowly wear away exposing new abrasive. A uniform, consistent surface is the result.
• Valgro-Fynex surface conditioning products work effectively from the very start, without a time-consuming break-in period.
• Valgro-Fynex products won't load up…unlike other products, which often accumulate surface material that reduces conditioning effectiveness.

1. Consistent performance throughout the products life.

2. Improvement in surface geometry.

3. No dressing of abrasive tool is essential - controlled stock removal.

4. Overall lower polishing cost.

5. Reduced tensile stress & overall higher quality finished parts.

6. Does not require any kind of 'breaking-in' period.

7. Perfect for Surface conditioning.

• Edge radius and burr removal
• Flashing removal
• Surfacing burr conditioning

Surface finish is an important element in any specification for stainless steel. For those applications in which appearance is important, finish is a design element and must be specified to avoid receiving a finish that is not appropriate to the application.

Finish – A Design Element

There are several good reasons for paying close attention to the finish designation. In architecture or other highly visible applications, the appearance of stainless steel is a critical design element and a misunderstanding or the wrong finish can alter the desired effect.

On the other hand, some fabrication operation in manufacturing stainless steel products, such as deep drawing, yield better results if the metal surface has a slightly rough texture to hold lubricants.

The surface on stainless steel from the mill or steel warehouse is either the result of processes used in producing the basic mill form or it is the result of subsequent operations performed specifically to alter the surface condition or appearance.

Mill processes include hot rolling, cold rolling, annealing and pickling. These operations are intended to bring the steel product to specific shape, dimension, and metallurgical condition and the resulting finish is generally referred to as a rolled (or unpolished) finish.

Subsequent mechanical operations, however, which include grinding, brushing, polishing and buffing, are intended primarily to change appearance of the metal surface. The finishes resulting from these operations are referred to as polished finishes.

Rolled finishes serve a very broad and practical use because they are usually the simplest to produce and they are generally the lowest in cost. Furthermore, some very clever and dramatic effects can be achieved with rolled finishes.

Standard finishes

Stainless steel flat products are usually produced from cast slabs by hot rolling and finishing on continuous hot rolling mills.

Hot rolling coils are further processed by annealing, de-scaling and cold reducing to specified thickness, than further annealing and de-scaling.

Rolling product finishes are designated by a system of numbers No. 1, 2D & 2B, satin, matt, Hairline and polished finished by No. 3, 4 & 8. Various other specific rolled pattern finishes are also in vogue. They are produced by rolling with special rolls in which designs are engraved /etched.

Identification of Surface Finish

Hot Rolled Finish – No.1 Finish

Slabs are hot rolled to plates/coils, annealed shot blasted and pickled. This result in a dull, slightly rough surface: quite suitable for industrial applications which generally involve a range of thicknesses.

Typical uses: Air heaters, annealing boxes, boiler baffles, duct, carburizing boxes, coal & ore handling systems, crystallizing pans, fire box sheets, furnace supports, conveyors, lining, damper, stacks, gas turbine parts, heat exchanger tubing supports and baffles, incinerators, industrial over liners, oil burner parts, pipes, rail coach/ wagon components, recuperate, refinery equipment, tube hangers etc.

Cold Rolled Finishes.

The starting material for cold rolling is a No.1 finish coil. Cold rolled material is supplied with the following standard mill finishes:

No.2D Finish

Material with a No.1 finish is cold rolled, annealed and pickled. This results in a uniform dull finish. Suitable for industrial application and eminently for severe deep drawing as the dull surface (which may be polished after fabrication) retains the lubricant during the drawing operation.

Typical uses: Automotive exhaust systems, builders’ hardware, chemical & petrochemical equipment, electric appliance parts, furnace parts, household ware, kitchen equipment, rail coach parts, trays & pans for chemical equipment etc.

No.2B Finish

Material with a 2D finish is given a subsequent light skin pass operation between polished rolls. A 2B finish is the most common finish for sheet material. It is brighter than 2D and is semi-reflective which in turn depends on the grade of stainless steel. It is commonly used for most deep drawing operation and is more easily polished to the final finishes required than in a 2D finish.

Typical Uses: Bake ware, chemical plant equipment, cook ware, dairy & food processing machinery, drums, dryers, dye house equipment, flatware, laundry equipment, paper mill equipment, pharmaceutical equipment, plumbing fixtures, refrigeration equipment, sheet metal products, small tanks, solar collector panels, washing machine parts, welded tubing & pipe for general service etc.

Mechanically Polished Finishes

The following finishes are all mechanically produced polished finishes. As well as being standard mill finishes, they are also applied to stainless steel articles and components to meet the required aesthetic criteria. It should be appreciated that factors such as hand polishing Vs mechanical polishing, polishing a flat product as against a component of complex shape and thickness and composition of material can affect the visual appearance of the final surface

Scratch grinding Finish: (Achieved by Valgro 60-80 Brush) This is a ground uniform finish obtained with 60-80 extra coarse grit Valgro abrasives brush. This finish creates uniform surface finish for subsequent operation for final finish.

It is a good starting surface finish for use in case of removal of handling scratch mark by grinding operation, where the surface will require further finishing operations to a finer. It can also be used as a final finish in certain applications.

No.3 Finish (Achieved by Valgro 100-120 Brush)

This is a ground unidirectional uniform finish obtained with Valgro 100-120 coarse grit abrasives brush or a Belt. In brush operation finish achieved uniform and consistent on each sheet. In belt operation finish is not achieve consistent. in starting belt is very aggressive and after some operation it wear very fast and finish is change, and frequent replacement required in belt to achieve similar finish.

It is a good intermediate or starting surface finish for use in such instances where the surface will require further polishing operations to a finer finish after subsequent fabrication or forming. It can also be used as a final finish in certain applications.

Typical Uses: Architectural components, brewery equipment, food processing, institutional kitchen equipment, light drawing followed by No.4 finish, scientific apparatus etc.

No.4 Finish (Achieved by Valgro 120-150 Brush)

This is a ground unidirectional finish achieve with VALGRO 120-150 grit abrasive brush. It is not highly reflective, but is a good general purpose finish on components which will suffer from fairly rough handling in service (e.g. restaurant equipment, Dairy equipment).

Factor affecting performance for finishing and polishing :

Surface speed : Since product speed has a significant effect on performance (cut, life and finish), it is important to select the proper speed for a particular operation and work piece.

Generally, low speeds are desired for generating a very uniform satin finish, for finishing aluminum alloys without lubricants and for composite or other soft material applications. High speeds are recommended when it is desired to remove or blend surface imperfections. High speed will result in faster cut, along with finer finishes.

Work Pressure : It is important that adequate pressure be used to generate the desired cut, finish and life. “Valgro-Fynex” wheels operate under work pressure of 0 to 40 pounds per inch of width. In the case of harder products, high pressures are usually necessary to gain the full benefits of the wheel.

Feed Speed (Dwell Time) : Feed speeds is directly related to product life, finish and cut. Lower feed speed means longer dwell time and thus, more work can be done on the work piece. When an operation is set up. An attempt should be made to use the fastest feed speed possible to obtain the desired results. This will give the best economic results from the standpoint of product life. In general, if product speed remains constant, fast feed speeds increase scratch length, and conversely, slow feed speeds shorten scratch length. This technique can be used to generate a particular decorative finish.

Lubricants / coolants : Coolants, like water and some water soluble oils, reduce heat, resulting in longer product life and greater cut. In the case of most oils or tallow lubricants produce lower surface roughness, i.e. grease, produces a finer surface finish than oil. It automatic or semi-automatic operations, it is desirable to use lubricants or coolants, whenever possible.

Oscillation : In many cases, such as decorative finishing and cleaning, it is desirable to incorporate an oscillatory motion for the purpose of increasing cut, breaking up directional scratch and producing a uniform finish. A good starting point is 150 CPM (ccle per minute) at a stroke of 9.5 mm (3/8 inches). This may be varied, depending on the particular result desired. In offhand operations, moving the part from side to side will provide an oscillating action and more uniform finish.

Product Hardness (Density) : “Valgro-Fynex” finishing wheels are available in three densities – soft, medium and hard. Generally, the softer products are used for decorative finishing. They confirm more readily to surface contours, along with generative a more uniform finish. The harder products are to be used for more difficult blending, cleaning and deburring operations.

1. Q & Q Resin Rubber

2. Polisher with speed rotation needed at work with 2 cloth rolling

3. Abrasive of Valgro and Kenda,

4. Carnuaba 8 of Valgro and Kenda ,

5. Sandpaper or bronze brush wire

• minimum speed around 900 per minutes, the color will gradually release off and turn even, suit brush off color that release a less or parts (brush off will not release all)
• maximum speed around 1200-2000 per minutes, the color will gradually release off. Spend less time to brush off but smooth is difficult to control. Good to brush off all or wanted a lot of brush off (brush off will take out entirely and leave only the background color to see)

1. If the rolling brush is a new one use sandpaper to pull the rolling before application. Be sure the touchable front is constantly smooth. If the rolling is old or dirty use sandpaper to retouch or use bronze brush rolling to clean before inserting the abrasive brush on the rolling.

2. Use abrasive to brush the unsmooth of another rolling and abrasive to varnish cloth rolling/ another leather, it is not advisable to use the same rolling for 2 types of brush

3. After brushing the Q rubber touch with rolling, use heat of 900 – 1,800 around per minute a suitable heat that makes the brush and a beautiful glazing shade

1. Q & Q colorful Sand-Washed sole sheet

2. Polisher with speed rotation for application with cloth rolling/1 valgro fynex scotch- bright roller

3. Abrasive of Kenda “Ledabuff 120”

4. Sandpaper 36-40

• Minimum speed 1000 per minutes, the color will gradually release off and constantly bias, good to brush some color off (sand-washed will not entirely off)
• Maximum speed 1800 per minutes, the color will quickly release using less time in brushing but difficult to control the smoothness

1. If the cloth rolling is new use sandpaper to trim before application. Be sure the front touches should be always bias. If the cloth roller is old or dirty use sandpaper to trim or use bronze brush wire to trim the roller into clean before putting abrasive to polish into the roller

2. After brushing by touching with Q rubber with roller, use speed 1,000 – 18,00 around per minute, a suitable speed, the brushing is more effective and beautifully varnish

• 1. DRESSING TOOL METHOD.
  
  -- With wheel rotating on spindle at operating speed, use a hand held dressing tool and slowly work back & forth across the face using short strokes. It is important to keep the dressing tool in motion. Don’t allow it to stay in one place on wheel for an extended length of time!
  
  --- When wheel appears round, go across face with long sweeping strokes.
  
  --- Finally, it is necessary to remove excess exposed fibres with a pumice stone being applied against work surface of rotating wheel. This should be done until abrasive grain is exposed.
• 2. COATED ABRASIVE METHOD.
  
  --- Take 36 or 40 grit sandpaper and wrap it around a piece of hardwood. With light pressure, hold it up against rotating wheel.
  
  --- Hold it firmly, not allowing it to bounce!
  
  --- When wheel’s running smoothly, check roundness by holding a light object across face of wheel. If no bounce occurs, the wheel has been properly dressed.
  
  --- Finally, it is necessary to expose the abrasive grain for optimum performance, simply use the end piece of hardwood or pumice stone and apply moderate to light pressure until you see wood dust.

• Processing delicate parts and softer metals such as aluminum and brass,

• De-burring parts with edge radius specifications below 0.003".(0.076 mm), and

• Producing a specific surface finish.

• The castings were painted before machining, and the de-burring operation could not remove the paint, and

• The de-burring operation could not produce a large edge break that could create a leakage path in the compressors.