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How to Distinguish the Quality of Abrasive Wire Brush Rolls?

Abrasive wire bristle roller refers to a brush roll made of abrasive wire bristles, which is widely used in the textile machinery, metal surface polishing, non-metallic grinding and other industries. How to distinguish the quality of the brush?

What is a high-quality grinding brush roll?

  • The bristles should not fall off during operation.

  • The bristles fixed in the base of the brush should use high-strength stainless steel materials to prevent rust.

  • Curved bristles should be in a wave-like shape.

  • The grinding particles inside the bristles of the bristle roller should not fall off due to the bend of the bristles.

  • Reasonable bristle height and density.

  • The bristles should have high hardness and toughness in humid environments.

  • The bristles should have good bending recovery.

  • The bristles should have good wear resistance.

The so-called abrasive wire refers to nylon wire with added abrasive materials such as silicon carbide (SIC) or alumina (AO), which is a new type of brush material. It is mostly used in the manufacturing of polishing brushes and grinding brushes. However, due to it being a new type of brush material, many brush manufacturers do not have a deep understanding of it. Sometimes, in order to compensate for the insufficient functionality of abrasive bristles, they make single modifications, which seem to solve the problem on the surface, but actually lead to more problems.

Most brush manufacturers have the following modification behaviors: increasing the diameter of the bristles, increasing the length of the bristles, and using larger abrasive materials.

Abrasive wire bristle roller

Increasing the diameter of the bristles

Many brush manufacturers believe that increasing the diameter of the bristles can improve the hardness and cutting force. However, this is not the case. High-quality abrasive bristles have an optimal balance point between hardness and flexibility: suitable hardness makes the product rigid, with good contact and grinding of the workpiece; suitable flexibility makes the brush have good rebound, which ensures the processing accuracy of the workpiece surface, reduces the wear and internal stress of the brush during grinding operations, and thus improves the service life of the brush, without causing breakage of the bristles.

Experiments have shown that under the same conditions, the abrasion of a 14mm diameter brush is twice that of a 12mm diameter brush.

The main problem with increasing the diameter of the bristles is that the density of the bristles decreases, fatigue resistance decreases, wear is faster, service life is shorter, the grinding stress increases, and the bristles are more prone to breakage. Therefore, the correct approach is to use finer diameter bristles as much as possible provided that the hardness of the brush meets the technical requirements.

Increasing the length of the bristles

Many brush manufacturers believe that discarded brushes are due to short bristle lengths, so increasing the length of the bristles will make them softer and more durable. In fact, this is a major mistake. During the polishing and grinding process, what really works is not the tangent surface of the bristles, but the side surface of the bristles. Therefore, simply increasing the length of the bristles inevitably increases the amplitude (angle) of each bristle swinging. Under the condition of 800-2500 revolutions per minute, the internal stress and fatigue coefficient of the bristle roots will be magnified, which will cause the abrasive bristles to break easily and the fine bristles to deform significantly.

Using larger abrasive materials

Using larger abrasive materials intends to improve the cutting force, which is understandable, but when the particle size does not change much, the effect of simply increasing the size of the abrasive can be negligible. On the contrary, it may have some side effects, because when the brush is working, the abrasive will generate a shear to the bristles themselves. The greater the angle of the bristle swing, the more obvious this will be.

In summary, the bristles of abrasive wire bristle rollers are a relatively special brush material, and must be used carefully. Every modification must go through repeated tests and comparisons before being mass-produced to ensure that the brush products meet user requirements.

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