By Doris Vrečko, Product Manager, Weiler Abrasives
Stainless steel is a material synonymous with durability, corrosion resistance and sleek aesthetics. It is the backbone of industries ranging from shipbuilding and heavy equipment fabrication to medical device manufacturing and architectural design.
However, working with stainless steel isn’t without its challenges. That’s where choosing the right wheels comes into play — helping transform the way users cut, grind and finish this resilient material.
Abrasives designed for stainless steel
The basic styles of abrasive products used to clean, finish, cut and grind stainless steel are the same as those used on carbon steel. But there are several differences in the makeup of these products that make their use easier and more productive.
For instance, cutting and grinding wheels that are labeled as contaminant-free or INOX boast a special formulation containing additives to ensure that they contain less than 0.1% of certain elements, such as iron, sulfur and chlorine. This formulation preserves the stainless steel’s corrosion-resistant properties, which are crucial for applications requiring pristine surface integrity. Bonded abrasive products labeled as INOX are contaminant-free. Whether or not a contaminant-free product is needed depends on the final requirements of the application. It’s also important to avoid using a product on stainless steel after it’s been used on carbon steel.
Coated abrasives designed for stainless steel typically feature an extra coating layer, or “topcoat,” that helps reduce heat buildup during the grinding and finishing processes, and wire brushes have stainless steel wires that do the cleaning.
It’s important to understand how stainless steel responds to finishing and why it’s so critical to use products specifically designed for this material. Doing so can save time and money while helping users achieve the desired results.
Cutting stainless steel: Precision and efficiency
Cutting stainless steel to the desired size and shape is the first critical step in fabrication. Cutting this material efficiently is crucial to maintain productivity and quality across many industries.
Look for wheel options that are designed specifically to tackle this task with precision, offering fast cut rates, reduced downtime and extended product life, which helps ensure cost effectiveness and fewer replacements. Certain wheels, like Tiger INOX 2.0 wheels from Weiler Abrasives, are engineered to minimize heat buildup to prevent the dreaded discoloration and maintain the integrity of the stainless steel. These wheels also feature a new blotter design that includes an industry-first Optimum Use Line. This line is a visual indicator that helps the user utilize the wheel to its full life to reduce wheel changeovers and help improve productivity while also reducing waste and abrasive spend.
Best practices for cutting stainless steel include using thinner wheels, such as the increasingly popular 1-millimeter options. Thinner wheels minimize heat and material waste, ensuring a clean cut every time. It’s also critical to avoid cross-contamination and always use tools dedicated to stainless steel to prevent compromising the material’s anti-corrosive properties.
QUICK TIP: Employ a slight sawing motion and apply consistent, steady pressure to enhance efficiency and extend wheel life.
Grinding stainless steel: Speed and precision
Following the initial cut, grinding stainless steel smooths out rough edges and surfaces, which is crucial for achieving precise dimensions and preparing the material for further finishing.
Bonded grinding wheels are ideal for removing large amounts of material quickly. Their advanced bond formulation prevents uneven edge wear and chipping, enhancing both safety and longevity. The Tiger 2.0 wheels from Weiler are designed with fiberglass cutback from the edge for aggressive grinding right out of the box. They also feature a QR code on each wheel so users can conveniently access crucial safety information where and when they need it.
Flap discs are another abrasives option for grinding stainless steel. These discs combine grinding and finishing in a single step, eliminating the need for frequent product changeovers. This dual functionality saves time and money, making flap discs particularly valuable for less experienced users. Look for flap discs designed with different flap configurations for higher material removal rates, a smoother feeling and longer product life.
QUICK TIPS: When using bonded grinding wheels, it's crucial to start with a pullback motion rather than a push to reduce the risk of gouging the material. Let the wheel’s design facilitate material removal without applying excessive force. When using flap discs, maintain a smooth, consistent motion and use the correct angle and minimal pressure to optimize the performance and lifespan of the discs.
Finishing stainless steel: Achieving the perfect finish
Finishing stainless steel to meet specific aesthetic and functional requirements is a meticulous process and a multistep journey. No one product does it all when it comes to finishing stainless steel. For example, it is common to start with a bonded abrasive for heavy stock removal, move to a flap disc to blend, and then use a resin fiber disc to blend the parent material to the weld before finally ending with a polishing or buffing disc.
It’s essential to start with the right abrasive based on the required finish, be it a non-directional, No. 4 finish or a mirror polish. Skipping steps in this process may save time initially, but it often leads to costly rework. Look for wheels that have an additional coating layer, which can help reduce heat buildup. This helps achieve a smoother finish and reduces the need for rework.
QUICK TIP: Keep the wheel moving in a consistent pattern to avoid heat concentration and potential damage to the workpiece.
Cleaning stainless steel: Maintaining surface integrity
Cleaning stainless steel surfaces and welds is essential to maintaining the integrity and appearance of the material.
Wire brushes equipped with stainless steel wires effectively remove contaminants without damaging the base material. Look for a brush designed to minimize premature wire failure to ensure durability and longevity. Brushes that deliver consistent results contribute to overall operational efficiency.
QUICK TIP: Brushes should always be operated at the highest practical speed with the lightest amount of pressure by the user. This allows the tips of the wires to do the work as the brush is designed.
Choosing products to maximize results with stainless steel
New products designed specifically for stainless steel can help improve productivity and finish quality when working with the material — and can be game-changers in stainless steel fabrication. These products address the unique challenges posed by stainless steel and offer solutions that enhance efficiency, safety and quality across cutting, grinding and finishing applications. They can also help users achieve the best possible results with minimal effort and maximum safety.
In addition to choosing a product designed for the specific application and the required finish, it’s also important to follow the steps of the finishing process and understand how stainless steel reacts. This will help reduce rework, save time and money, and get the best results with stainless steel.