PFERD Tools for Use on Aluminium

<strong>PFERD</strong> <strong>Tools</strong> <strong>for</strong> <strong>Use</strong> on AluminiumIntroduction, Table of ContentsAugust Rüggeberg GmbH & Co. KG, Marienheide/Germany, develops,produces and markets tools <strong>for</strong> surface finishing and cutting materialsunder the brand name <strong>PFERD</strong>. For more than 100 years, <strong>PFERD</strong> has beena distinctive brand mark <strong>for</strong> excellent quality, top per<strong>for</strong>mance andeconomic value.<strong>PFERD</strong> produces a comprehensive tool range <strong>for</strong> the most diverse aluminiummachining and finishing tasks. All of these products have been purpose-developed<strong>for</strong> their respective application and have proven themselves in practice.In the present issue of <strong>PFERD</strong> PRAXIS we have summarized our experience ofmany years, including the very latest know-how, on the specific machining andper<strong>for</strong>mance behaviour of tools <strong>for</strong> use on aluminium and its diverse alloys.AluminiumA Material with a Future ......................3More than 1,000 Alloys ......................4Properties of Aluminium ......................5Machinability Groups SOFT, TOUGH, HARD ...6Aluminium Machining Recommendations .........7Important Safety Instructions, oSa,<strong>PFERD</strong>ERGONOMICS ........................8Machining Processes ..........................9On pages 10-24 we show you which <strong>PFERD</strong> tools are bestsuited <strong>for</strong> solving the various application needs in workingwith aluminium.Table of Contents .......................... 9Abrasive Cut-Off and Cut-Out Work ......... 10-11Deburring ............................. 12-13Preparation <strong>for</strong> Welding – Joint Preparation ....14-15Preparation <strong>for</strong> Welding – Surface Machining ..16-17Weld Dressing ..........................18-19Fine Grinding and Finishing ................20-21Texturing ..............................22-23Polishing .................................24<strong>Tools</strong> <strong>for</strong> <strong>Use</strong> on Aluminiumfrom <strong>PFERD</strong> Catalogues 201-209 ...............25On pages 26-36 we describe the special properties ofindividual groups of tools which are particularly wellsuited <strong>for</strong> use on aluminium, adhering to the structure ofour <strong>PFERD</strong> Catalogues 201-209.Table of Contents ..........................25Files .....................................26Rotary Cutters .............................27Hole Saws and Hole Cutters ..................28Mounted Points ............................29Grinding and Polishing <strong>Tools</strong> ...............30-31Cut-Off Wheels ............................32Rein<strong>for</strong>ced Grinding Wheels ..................33POLIFAN ® Flap Discs ........................34Industrial Power Brushes .....................35Power <strong>Tools</strong> ...............................362

AluminiumA Material with a FutureThe use of aluminium and its alloys is growing, and so are metalworkingapplications involving this material – why?Aluminium, at about 8%, is the most abundant element in the earth’s crust afteroxygen and silicon. Given the material properties of aluminium and its alloys, i.e.■■extreme durability,■■low weight,■■corrosion resistance,■■recyclability,aluminium materials have become progressively more widespread in recent years.The development of ever more lightweight parts which must nevertheless meetunchanged strength requirements has given rise to an ever-growing use ofaluminium alloys. The latter can be <strong>for</strong>med into virtually any shape using a varietyof industrially available processes (casting, rolling, extruding), which opens up awealth of options to the industrial user or processor of aluminium alloys. At thelevel of joining technology, one focus of development lies on adapting commonmetal-joining processes so as to make them suitable <strong>for</strong> use with aluminium alloys.In many segments and branches of industry, materials have to meet exactingdemands regarding surface quality, environmental per<strong>for</strong>mance and safety.Advanced transport systems are no longer conceivable without the use oflightweight aluminium components. In addition, aluminium as a material groupperfectly satisfies today’s increasingly stringent environmental requirementsconcerning product recyclability.Our goal is to provide you with optimum results and unsurpassed costefficiency in your aluminium machining and finishing work.By now, nearly all welding processes <strong>for</strong> joining aluminium and its alloys havebecome available on an industrial scale, reflecting the special properties of thismaterial.Special aluminium alloys have become the material of choice in a wide range ofapplications from housings, vehicles, tank construction, mechanical and facadeengineering to doors, windows, foundations, heat exchangers and aerospacecomponents.An increasingly numerous user community is aiming <strong>for</strong> optimum results andmaximum cost-efficiency in aluminium machining or processing. At <strong>PFERD</strong>, thedevelopment of new aluminium-working tools has there<strong>for</strong>e been a high priority<strong>for</strong> decades.3

AluminiumMore than 1,000 AlloysIs all aluminium the same?Unsurprisingly, no. The catch-all term “aluminium” refers to a group of alloyswhich share aluminium as their main constituent – a broad range of metalliccompounds based on pure aluminium and one or more additional elements.Over 1,000 aluminium alloys exist today. They all have been purpose-developedto improve the properties of the base metal.What do the various aluminium alloys have in common?■■They all contain at least 60% pure aluminium.■■Their specific gravity is much lower than that of steel.■■They are usually corrosion-resistant.■■They have an excellent electrical and thermal conductivity.Which distinctions are made between the various aluminium alloys?■■Wrought alloys and associated weld filler materials(sheet metal, strip, sections, rods, tubes, <strong>for</strong>gings)■■Casting alloys and associated weld filler materials(sand casting, gravity die casting, precision casting)In addition, one must differentiate between■■Heat-treatable and■■Non-heat-treatable alloys.In heat-treatable material, the state of the alloy is of key importance <strong>for</strong> itsmachining properties. By means of heat treatment processes such as agehardening or soft annealing, in combination with the use of different mixingratios, entirely different material properties can be achieved. The followingcharacteristics can all be modified:■■Strength■■Density■■Corrosion resistance■■Conductivity■■Machinability■■Visual appearance of the bare metal4

AluminiumProperties of AluminiumWhich factors influence aluminium machining?The greatest challenge with most aluminium alloys lies in their machinabilityproperties. Depending on the alloy and its heat treatment condition, the materialmay prove soft and ductile or hard and brittle in the machining process. Hardnessis an important alloy classification criterion. A less-than-optimum geometry of thecutting faces will result in edge build-up, an effect commonly responsible <strong>for</strong> toolloading problems. It may also dramatically reduce tool life.Given the high oxygen affinity of aluminium, a dense layer of oxide will <strong>for</strong>m on itssurface upon exposure to air and water. This oxide protects the underlying metalfrom corrosion, albeit not fully.What should be borne in mind with regard to mechanical machiningof surfaces?The material’s corrosion behaviour is influenced strongly by its surface propertiesand the way these are changed by grinding, polishing or brushing.While every surface smoothing operation will enhance the corrosion resistanceof aluminium, roughing jobs will generally diminish it. Particles of <strong>for</strong>eign matterimpressed into the surface will likewise impair the material’s corrosion resistance.Mechanical surface machining of pure aluminium or alloys having a Brinellhardness of less than 40 HB requires caution and experience.The pressure exercised during grinding and polishing must be adapted to thematerial’s specific hardness since soft alloys tend to become gummy. In addition,grinding dust or abrasive particles may be impressed into the surface, destroyingthe enhanced visual appearance one intends to produce.Photo: Otto FuchsMany new aluminium-based alloys willstill be developed in the future, giventhat the properties of this materialmake it indispensable in our modernworld. Aluminium has there<strong>for</strong>e alsobeen called the ‘metal of the newcentury’.5

AluminiumMachinability Groups SOFT, TOUGH, HARDFor optimum machining results on aluminium and its diverse alloys according to EN standards, <strong>PFERD</strong> distinguishes threemachinability groups (Soft, tough, hard). Each of these represents a different Brinell hardness range. On thefollowing pages, suitable <strong>PFERD</strong> tools are allocated to each of these groups.Photo: Otto FuchsPhoto: Otto FuchsHBMACHINABILITY GROUPSOFTMACHINABILITY GROUPTOUGHMACHINABILITY GROUPHARD154060n Non-heat-treatable wrought alloysEN AW 1,000-1,999EN AW 2,000-2,999EN AW 3,000-3,999EN AW 5,000-5,999n Heat-treatable wrought alloysin a soft stageEN AW 6,000-6,999EN AW 7,000-7,999n Welding filler materialsn Non-heat-treatablealuminium casting alloysEN AC 5,000-5,999EN AB 5,000-5,999n Heat-treatable aluminiumcasting alloys in a soft stageEN AC 4,000-4,999EN AB 4,000-4,999n Welding filler materialsn Wrought alloys with lowsilicon contentsEN AW 4,000-4,999n Heat-treatable wrought alloysEN AW 6,000-6,999EN AW 7,000-7,999100n Heat-treated aluminiumcasting alloys with siliconcontents < 12%EN AC 4,000-4,999EN AB 4,000-4,999n Non-heat-treated aluminiumcasting alloys with silicon content< 12%EN AC 4,000-4,999EN AB 4,000-4,999120n Heat-treated wrought alloyswith chipbreaking properties130140150IndexHB = Brinell hardnessEN = European StandardAB = Alloyed aluminiumingotsAC = Aluminium castingsAW = Wrought aluminiummaterialsn Aluminium casting alloys withsilicon content > 12%(responsible <strong>for</strong> high tool wear)n Self-hardening aluminium castingalloys without siliconEN AC 2,000-2,999EN AC 7,000-7,999EN AB 2,000-2,999EN AB 7,000-7,999n Heat-treated aluminiumcasting alloys without siliconEN AC 2,000-2,999EN AC 7,000-7,999EN AB 2,000-2,999EN AB 7,000-7,999n Weld filler materialsn Heat-treated wrought alloysEN AW 6,000-6,999EN AW 7,000-7,999n Weld filler materials6

AluminiumAluminium Machining RecommendationsWhich recommendations must be observed in aluminium machining?Cutting speed [RPM]■■For an optimum surface finish, the cutting speed needs to be adapted to themachining process as well as to the alloy and its heat treatment state. Observethe RPM recommendations on the following pages.Contact pressure■■Despite the good thermal conductivity of aluminium, local overheating due toexcessive grinding pressure may cause microstructural alterations in theaffected areas. As a result, the material’s visual appearance may be impairedafter subsequent electrolytic surface treatment.■■Avoid high contact pressures to prevent abraded particles and abrasive materialfrom getting impressed into the workpiece surface.■■Compared with conventional steel materials, aluminium alloys must be groundwith a reduced contact pressure. This is the only way to avoid intense heatingof the workpiece and to achieve a good surface finish.Cooling■■The use of grinding oils and grinding grease prevents excessive temperaturebuild-up and helps to achieve good cooling, especially with finer-grained abrasives.Corrosion■■To avoid contact corrosion due to the presence of abraded material on themachined surface, the tools employed (e.g. brushes) must not consist of copperalloys or steel.■ ■ The use of abrasive or polishing wheels or brushes which have previously beenused on other metals is likewise to be avoided. A strict separation of tools isabsolutely necessary.7

■ Lower vibrations■ Reduced noise■ Less dust development■ Optimized haptics at workThe Focus is on PeopleTRUST BLUE1Noise and Vibration Limits EU occupational safety directives transposed into German national law Increased safety and improved health protection at workAluminiumImportant Safety Instructions, oSa, <strong>PFERD</strong>ERGONOMICSSafety notes of the German Association of Workmen’sCompensation InsurersIn its Rules <strong>for</strong> Safety and Health at Work (BGR 109), the GermanAssociation of Workmen’s Compensation Insurers defines practicesand precautions aimed at preventing hazards such as dust fires anddust explosions during grinding, brushing and polishing.PRECAUTIONS AGAINST LIKELY HAZARDSThe publication issued by the Association of Workmen’s Compensation Insurersprovides in<strong>for</strong>mation on aspects such as:■■design of metalworking machines, associated equipment, workshops and storagerooms;■■extraction, conveyance, collection, storage and transport of dusts and associatedsludges;■■machining and separation of different materials (aluminium and sparking materialssuch as steel);■■avoidance of ignition sources;■■extinguishing systems and fire fighting;■■cleaning and maintenance;■■personal protective equipment and workwear;■■operating instructions, training and equipment inspection;■■hazard assessment, explosion protection document, cleaning and maintenanceschedules;■■regulations of the German Association of Workmen’s Compensation Insurers,rules, principles and in<strong>for</strong>mation, as wells as laws, ordinances and standards.Noise• Ear protection complying with EN352 is recommended <strong>for</strong> all applications where the workpieceor machine is hand-held, irrespective of the noise level.• Ensure that the correct abrasive product is selected. An unsuitable product can produceexcessive noise.Vibration• Processes where the workpiece or machine is hand-held can cause vibration injury.• Action needs to be taken if tingling, pins and needles or numbness is experienced after 10minutes continuous use of the abrasive product.• The effects of vibration are more pronounced in cold conditions so keep the hands warm andexercise hands and fingers regularly. <strong>Use</strong> modern equipment with low vibration levels.• Maintain all equipment in good condition and stop the machine and have it checked ifexcessive vibration occurs.• <strong>Use</strong> good quality abrasive products and keep them in good condition during their life.• Maintain mounting flanges and back-up pads in good condition and replace if worn ordistorted.• Do not grip the workpiece or machine too tightly and do not exert excessive pressure on theabrasive product.• Avoid continuous use of the abrasive product.• <strong>Use</strong> the correct product. An unsuitable product can produce excessive vibration.• Don’t ignore the physical symptoms of vibration - seek medical advice.Disposal of abrasives• <strong>Use</strong>d or defective abrasives should be disposed in accordance with local or nationalregulations.• Further in<strong>for</strong>mation can be obtained from material safety data sheets provided by the supplier.• Be aware that the abrasive product may be contaminated with material from the workpiece orprocess after use.• Disposed abrasive products should be damaged to prevent them from being taken from wasteskips and reused.Safety recommendationsPlease observe FEPA safety recommendations as well as the pictograms.National AssociationTel.: 0228 / 635587Fax: 0228 / 635399National Associationwww.fepa-abrasives.orgIssue 1 – Nov 2004Important noticeEvery ef<strong>for</strong>t has been made toensure that all in<strong>for</strong>matinonsupplied in this leaflet is accurateand up to date. We can notaccept, however, responsibility<strong>for</strong> any error or omission, nor <strong>for</strong>any consequential loss or damageso arising (E & OE).© FEPA 2004Not permitted <strong>for</strong>= Wear eye protection! =wet grinding!= Wear gloves! == Wear hearing protection! == Wear a respirator! ==Only permitted witha backing pad!<strong>PFERD</strong>ERGONOMICSTool selection affects the workingsituation of the user and his completeworking environment. It not only has agreat influence on the most economicalproblem solution, it also has a majorinfluence on the health, safety andcom<strong>for</strong>t of the tool user.To be able to fulfill these increasedrequirements. <strong>PFERD</strong>ERGONOMICSsupplies solutions <strong>for</strong>■■Lower vibrations■■Reduced noise■■Less dust development■■Optimized hapticsNot permitted <strong>for</strong>face grinding!Do not use ifdamaged!Leaflet supplied and endorsed byAugust Rüggeberg GmbH& Co. KG<strong>PFERD</strong>-WerkzeugeHauptstraße 1351709 MarienheideTel. (0 22 64) 90Fax (0 22 64) 94 00www.pferd.com · info@pferd.comNot permitted <strong>for</strong> hand-held ormanually guided grinding!= Read the instructions!<strong>PFERD</strong>ERGONOMICSHealth and Safety at the WorkplaceFor further in<strong>for</strong>mation and suitable<strong>PFERD</strong> tools, see the brochures“<strong>PFERD</strong>ERGONOMICS – The Focus ison People” and “Health and Safety atthe Workplace – Noise and VibrationLimits“.FEDERATION·OF·EUROPEANPRODUCERS·OF·ABRASIVESSAFETY RECOMMENDATIONS FORTHE USE OF ABRASIVE PRODUCTSPASS ON THIS LEAFLET TO THOSE USING THE ABRASIVE PRODUCTThe recommendations contained in this leaflet shoult be followed byall users of abrasive products in the interests of their personal safety.GENERAL PRINCIPLES OF SAFETYAbrasive products improperly used can be very dangerous.• Always follow the instructions provided by the abrasive product and machinesupplier.• Ensure that the abrasive product is suitable <strong>for</strong> its intended use. Examine all abrasive products<strong>for</strong> damage or defects be<strong>for</strong>e mounting.• Follow the correct procedures <strong>for</strong> handling and storage of abrasive products.Be aware of the hazards likely during the use of abrasive products and observe therecommended precautions to be taken:• Bodily contact with the abrasive product at operating speed.• Injury resulting from product breakage during use.• Grinding debris, sparks, fumes and dust generated by the grinding process.• Noise.• Vibration.<strong>Use</strong> only abrasive products con<strong>for</strong>ming to the highest standards of safety. These products willbear the relevant EN standard number and/or the inscription “oSa”.• EN12413 <strong>for</strong> Bonded Abrasives.• EN13236 <strong>for</strong> Superabrasives.• EN13743 <strong>for</strong> Specific Coated Abrasives (vulcanised fibre discs, flap wheels, flapdiscs and spindle-mounted flap wheels).Never use a machine that is not in good working order or one with defective parts.Employers should carry out a risk assessment on all individual abrasive processes to determine theappropriate protective measures necessary. They should ensure that their employees are suitablytrained to carry out their duties.This leaflet is only intended to provide basic safety recommendations. We strongly recommendthat or more detailed in<strong>for</strong>mation on the safe use of abrasive products, comprehensive SafetyCodes are available from FEPA or your National Trade Association:• FEPA Safety Code <strong>for</strong> Bonded Abrasives and Precision Superabrasives.• FEPA Safety Code <strong>for</strong> Superabrasives <strong>for</strong> Stone and Construction.• FEPA Safety Code <strong>for</strong> Coated Abrasives.FEPA safety recommendations are available <strong>for</strong>download at www.pferd.com.<strong>PFERD</strong> is an oSafounding memberTogether with othermanufacturers, <strong>PFERD</strong>has undertaken voluntarily to producequality tools con<strong>for</strong>ming to themost exacting safety standards.oSa member companies manufactureto the most stringent specificationsworldwide and are committedto continuous product safety andquality monitoring.<strong>PFERD</strong> tools carry the oSa mark.Have you got any questions aboutgrinding safety? Either during ourtraining seminars of our <strong>PFERD</strong>-AKADEMIE or through our field staffat your site – <strong>PFERD</strong> will be happy toprovide advice.8

Machining ProcessesTable of ContentsPageAbrasive Cut-Off and Cut-Out Work10-11Deburring12-13Preparation <strong>for</strong> Welding – Joint Preparation14-15Preparation <strong>for</strong> Welding – Surface Machining16-17Weld Dressing18-19Fine and Finishing Work20-21Texturing22-23Polishing24In the present <strong>PFERD</strong> PRAXIS issue, power tools and prime mover systems are symbolised by the following pictograms:ManualapplicationsStraightgrindersAnglegrindersBelt grindersFlexible shaftdrivesRobotapplicationsStationaryapplications9

Machining ProcessesAbrasive Cut-Off and Cut-Out WorkDescription of machining tasks:■■Cutting off sections, sheet metal,risers and pipes■■Producing cut-outs in tanks andswitchgear cabinets, e.g. <strong>for</strong> connectionsand pipe penetrations■■Producing cut-outs and notches insectional material and thin-walledpartsMACHINABILITY GROUPSOFTHSS hole sawsTC hole cutters15-60 HBCut-off wheels30-76 mm A 60 P SGMACHINABILITY GROUPTOUGHHSS hole sawsTC hole cutters40-150 HBCut-off wheels30-76 mm A 60 P SGMACHINABILITY GROUPHARDTC hole cuttersCut-off wheels30-76 mm A 60 P SGPhoto: Otto Fuchs100-150 HB10

Machining ProcessesAbrasive Cut-Off and Cut-Out WorkCut-off wheelsA 24/30/46/60 N SG-ALUCut-off wheelsA 24/30/46/60 N SG-ALUCut-off wheelsA 60 R SG-INOX40-150 HB15-60 HBCut-off wheelsA 24/30/46 N SG-ALUCut-off wheelsC 36 K SG-CHOPCut-off wheelsA 60 R SG-INOXCut-off wheelsC 30/46/60 R SGCut-off wheelsC 36 L SG-TABLE100-150 HB11

Machining ProcessesDeburringDescription of machining tasks:■■Deburring of edges,cut-outs and contours■■Chamfering■■Removing flash from castingsMACHINABILITY GROUPSOFTTC burrZ-ALUPoliflex ® finegrinding point TXAbrasive spiral bandsGSBZ-COOL, CO-COOLTC burrZ-ALU + coatingCOMBIDISC ®abrasive discsA-COOL, SiCGrinding oils 412 ALU15-60 HBPhoto: Otto FuchsHSS rotary cutterZ-ALUMounted pointsHardness F-ALUMounted pointsHardness LFan grindersZ-COOL, SiC,CO-COOLFlap wheelsPOLISTARPOLINOX ® unitizedwheels PNERMounted wheelbrushes, individualfilament type, RBU SiC/INOX, RBUIT INOXWheel brushes witharbor hole, individualfilament type,RBU SiC/INOXMACHINABILITY GROUPTOUGHTC burrZ-ALUPoliflex ® finegrinding point TXGrinding oils 412 ALU40-150 HBTC burrZ-ALU + coatingHSS rotary cutterZ-ALUMounted pointsHardness F-ALUMounted pointsHardness LCOMBIDISC ®abrasive discsA-COOL, SiC,CO-COOLFan grindersSiC, CO-COOL,Z-COOLPOLISTARAbrasive spiral bandsGSBZ-COOL, CO-COOLPOLINOX ® unitizedwheels PNERMounted wheelbrushes, individualfilament type,RBU SiC/INOXMounted wheelbrushes, individualfilament type,RBU INOX,RBUIT INOXWheel brushes witharbor hole, individualfilament type,RBU SiC/INOXMACHINABILITY GROUPHARDTC burrZ-ALUPoliflex ® finegrinding point TXGrinding oils 412 ALU100-150 HBPhoto: Otto FuchsTC burrZ-ALU + coatingTC burrZ-3Mounted pointsHardness F-ALUMounted pointsHardness MCOMBIDISC ®abrasive discsA-COOL, CO-COOL,SiCFan grindersZ-COOL, SiC,CO-COOLPOLISTARAbrasive spiral bandsGSBZ-COOL, CO-COOLPOLINOX ® unitizedwheels PNERMounted wheelbrushes, individualfilament type,RBU SiCMounted wheelbrushes, individualfilament type, RBUINOX, RBUIT INOXMounted wheelbrushes, individualfilament type,RBU SiC/INOX12

Machining ProcessesDeburringFibre discsA-COOL,CO-COOLPOLIFAN ®flap discsSG-A-COOLShort beltsA-COOL,CO-COOLTC burrsZ-ALU,Z-ALU + coatingRaspsCOMBICLICK ®A-COOL,CO-COOL, SiCGrinding oils412 ALURein<strong>for</strong>cedgrinding wheelsA 24 N SG-ALURein<strong>for</strong>cedgrinding wheelsC 24 Q SGFlaring cupbrush threaded,individual filamenttype, knotted,KBU INOX,KBG INOXWheel brusheswith arbor hole/threaded, knotted,RBG CT INOX,RBGIT CT INOXDisc brushes,individual filamenttype,DBUR SiCLong beltsGrinding oils412 ALUHSS rotary cutterZ-ALUWheel brushesw. arbor hole, individ.filam. typeRBU SiC/INOXMounted wheelbrushes, individualfilament type,RBU SiC/INOX,RBUIT INOXDisc brushes,individ. filam.type, DBU SiCFiles <strong>for</strong> soft metalPLUS ® fileMachinist‘s file C1Milled tooth fileInterior brushesthreaded,IBU SiC/INOX15-60 HBFibre discsA-COOL,CO-COOLPOLIFAN ® flap discsSG-A-COOL,SGP-CO-COOLShort beltsA-COOL,CO-COOLTC burrsZ-ALU,Z-ALU + coatingFiles <strong>for</strong> soft metalCOMBICLICK ®A-COOL,CO-COOL, SiCGrinding oils412 ALURein<strong>for</strong>cedgrinding wheelsA 24 N/O SG-ALURein<strong>for</strong>cedgrinding wheelsC 24 Q SGFlaring cupbrush threaded,individual filamenttype, knotted,KBU INOX,KBG INOXWheel brusheswith arbor hole/threaded, knotted,RBG CT INOX,RBGIT CT INOXDisc brushes,individual filamenttype, DBUR SiCLong beltsGrinding oils412 ALUHSS rotary cutterZ-ALUWheel brusheswith arbor hole,individual filamenttypeRBU SiC/INOXMounted wheelbrushes, individualfilament type,RBU SiC/INOX,RBUIT INOXDisc brushes,individualfilament type,DBU SiCPLUS ® fileMachinist‘s file C1Milled tooth fileInterior brushesthreaded,IBU SiC/INOX40-150 HBFibre discsA-COOL,CO-COOLCOMBICLICK ®A-COOL,CO-COOL, SiCGrinding oils412 ALURein<strong>for</strong>cedgrinding wheelsA 24 O SG-ALURein<strong>for</strong>cedgrinding wheelsC 24 Q SGPOLIFAN ®flap discsSG-A-COOL,SGP-CO-COOLFlaring cupbrush threaded,individual filamenttype, knotted,KBU INOX,KBG INOXWheel brusheswith arbor hole/threaded, knotted,RBG CT INOX,RBGIT CT INOXDisc brushes,individual filamenttype, DBUR SiCShort beltsA-COOL,CO-COOLLong beltsGrinding oils412 ALUTC burrZ-ALUTC burrZ-ALU + coatingWheel brusheswith arborhole, individualfilament typeRBU SiC/INOXMounted wheelbrushes, individualfilament type,RBU SiC/INOX,RBUIT INOXDisc brushes,individualfilament type,DBU SiCFiles <strong>for</strong> soft metalPLUS ® fileMachinist‘s file C1Milled tooth fileDiamond filesInterior brushesthreaded,IBU SiC/INOX100-150 HB13

Machining ProcessesPreparation <strong>for</strong> Welding – Joint PreparationDescription of machining tasks:■■Chamfering■■V-seam preparation■■Grinding out shrink holes■■Preparation of repair weldsMACHINABILITY GROUPSOFTTC burrZ-ALUAbrasive spiral bandsGSBZ-COOL, CO-COOLTC burrZ-ALU + coatingPOLIROLL ®15-60 HBHSS rotary cutterZ-ALUMounted pointsHardness F-ALUCOMBIDISC ®abrasive discsA-COOL,CO-COOL, SiCGrinding oils412 ALUMounted pointsHardness LMACHINABILITY GROUPTOUGHTC burrZ-ALUMounted pointsHardness LGrinding oils412 ALUTC burrZ-ALU + coatingAbrasive spiral bandsGSBZ-COOL, CO-COOL40-150 HBTC burrZ-ALU PLUSHSS rotary cutterZ-ALUMounted pointsHardness F-ALUPOLIROLL ®COMBIDISC ®abrasive discsA-COOL,CO-COOL, SiCMACHINABILITY GROUPHARDTC burrZ-ALUMounted pointsHardness MGrinding oils412 ALU100-150 HBTC burrZ-ALU + coatingTC burrZ-ALU PLUSTC burrZ-3PMounted pointsHardness F-ALUAbrasive spiral bandsGSBZ-COOL, CO-COOLPOLIROLL ®COMBIDISC ®abrasive discsA-COOL,CO-COOL, SiC14

Machining ProcessesPreparation <strong>for</strong> Welding – Joint PreparationFibre discsA-COOL,CO-COOLCOMBICLICK ®A-COOL,CO-COOL, SiCGrinding oils412 ALURein<strong>for</strong>cedgrinding wheelsA 24 N SG-ALURein<strong>for</strong>cedgrinding wheelsA46 H SGP-WHISPER-ALUPOLIFAN ®flap discsSG-A-COOLShort beltsA-COOL, CO-COOLLong beltsGrinding oils 412 ALURaspsFiles <strong>for</strong> soft metalPLUS ® fileMachinist‘s file C115-60 HBMilled tooth fileFibre discsA-COOL,CO-COOLCOMBICLICK ®A-COOL,CO-COOL, SiCRein<strong>for</strong>cedgrinding wheelsA46 H SGP-WHISPER-ALUPOLIFAN ®flap discsSG-A-COOLShort beltsA-COOL, CO-COOLLong beltsFiles <strong>for</strong> soft metalPLUS ® fileGrinding oils412 ALURein<strong>for</strong>cedgrinding wheelsA 24 N/O SG-ALUGrinding oils 412 ALUMachinist‘s file C1Milled tooth file40-150 HBFibre discsA-COOL,CO-COOLPOLIFAN ®flap discsSG-A-COOLShort beltsA-COOL, CO-COOLFiles <strong>for</strong> soft metalCOMBICLICK ®A-COOL,CO-COOL, SiCLong beltsPLUS ® fileGrinding oils412 ALURein<strong>for</strong>cedgrinding wheelsA 24 O SG-ALUGrinding oils 412 ALUMachinist‘s file C1Milled tooth file100-150 HBRein<strong>for</strong>cedgrinding wheelsA46 H SGP-WHISPER-ALUDiamond files15

Machining ProcessesPreparation <strong>for</strong> Welding – Surface MachiningDescription of machining tasks:■■Removing oxide skin■■Cleaning and removal ofimpurities without significantdimensional changes15-60 HBMACHINABILITY GROUPSOFTCOMBIDISC ®non-woven discsVRW/VRH/PNERPoliflex ®fine grinding toolsPUR/GRPOLINOX ® -mounted pointsPNZ/PNL/PNR/PNGPOLINOX ®ring wheelsPNZ/PNL/PNR/PNG/PNERMounted wheelbrushes, individualfilament type,RBU SiCMounted wheelbrushes, individualfilament type,RBU INOX,RBUIT INOXWheel brushes witharbor hole, individualfilament type,RBU SiC/INOX40-150 HBMACHINABILITY GROUPTOUGHCOMBIDISC ®non-woven discsVRW/VRH/PNERPoliflex ®fine grinding toolsGR/TXPOLINOX ®mounted pointsPNZ/PNL/PNR/PNGPOLINOX ®ring wheelsPNZ/PNL/PNR/PNG/PNERMounted wheelbrushes, individualfilament type,RBU SiCMounted wheelbrushes, individualfilament type,RBU INOX,RBUIT INOXWheel brushes witharbor hole, individualfilament type,RBU SiC/INOX100-150 HBMACHINABILITY GROUPHARDPhoto: Otto FuchsCOMBIDISC ®non-woven discsVRW/VRH/PNERPoliflex ®fine grinding toolsGR/GHR/TXPOLINOX ®mounted pointsPNZ/PNL/PNR/PNGPOLINOX ®ring wheelsPNZ/PNL/PNR/PNG/PNERMounted wheelbrushes, individualfilament type,RBU SiCMounted wheelbrushes, individualfilament type,RBU INOX,RBUIT INOXWheel brushes witharbor hole, individualfilament type,RBU SiC/INOX16

Aluminium Working ProcessesPreparation <strong>for</strong> Welding – Surface MachiningPOLIVLIES ®flap discsPOLICLEAN ®discPOLINOX ®unitized wheelsPNERPOLINOX ®unitized discPNERFlaring cupbrush threaded,individualfilament type,KBU INOXWheel brushes<strong>for</strong> anglegrindersRBU INOXDisc brushes,individualfilament type,DBUR SiCNon-woven abrasive beltsFiles <strong>for</strong> softmetalPLUS ® fileMachinist‘sfile C1Milled toothfileNon-woveneconomy rollsPOLIVLIES ®hand padsManualbrushes <strong>for</strong>precisionmechanics15-60 HBPOLIVLIES ® selfadhesivediscsAbrasivesheetsPOLIVLIES ®flap discsPOLICLEAN ®discPOLINOX ®unitized wheelsPNERPOLINOX ®unitized discPNERFlaringcup brushthreaded,individualfilament type,KBU INOXWheel brushes<strong>for</strong> anglegrindersRBU INOXDisc brushes,individualfilament type,DBUR SiCNon-woven abrasive beltsFiles <strong>for</strong> softmetalPLUS ® fileMachinist‘sfile C1Milled toothfileNon-woveneconomy rollsPOLIVLIES ®hand padsManualbrushes <strong>for</strong>precisionmechanics40-150 HBPOLIVLIES ®self-adhesivediscsAbrasivesheetsPOLIVLIES ®flap discsPOLICLEAN ®discPOLINOX ®unitized wheelsPNERPOLINOX ®unitized discPNERFlaringcup brushthreaded,individualfilament type,KBU INOXWheel brushes<strong>for</strong> anglegrindersRBU INOXDisc brushes,individualfilament type,DBUR SiCNon-woven abrasive beltsFiles <strong>for</strong> softmetalPLUS ® fileMachinist‘sfile C1Milled toothfileNon-woveneconomy rollsPOLIVLIES ®hand padsManualbrushes <strong>for</strong>precisionmechanics100-150 HBPOLIVLIES ®self-adhesivediscsAbrasivesheets17

Machining ProcessesWeld DressingDescription of machining tasks:■■Smoothing weld seams■■Removing defects■■Cleaning■■Levelling■■Reworking repair welds15-60 HBMACHINABILITY GROUPSOFTTC burrZ-ALUTC burrZ-ALU + coatingHSS rotary cutterZ-ALUMounted pointsHardness F-ALUMounted pointsHardness LAbrasive spiral bandsGSBZ-COOL, CO-COOLCOMBIDISC ®abrasive discsA-COOL, CO-COOL,SiCGrinding oils 412 ALUMounted wheelbrushes, individualfilament type,RBU INOX 0,30,RBUIT INOX 0,30Wheel brushes witharbor hole, individualfilament typeRBU INOXPencil brushes,knotted,SINGLETWIST ®PBGS INOX,PBGSIT INOXPencil brushes,individual filamenttype, PBU SiCPencil brushes,individual filamenttype, PBU INOX,PBUIT INOX40-150 HBMACHINABILITY GROUPTOUGHTC burrZ-ALUTC burrZ-ALU + coatingTC burrZ-ALU PLUSHSS rotary cutterZ-ALUMounted pointsHardness F-ALUMounted pointsHardness LAbrasive spiral bandsGSBCO-COOLCOMBIDISC ®abrasive discsA-COOL,CO-COOL, SiCGrinding oils 412 ALUMounted wheelbrushes, individualfilament type,RBU INOX 0,30,RBUIT INOX 0,30Wheel brushes witharbor hole, individualfilament typeRBU INOXPencil brushes,knotted,SINGLETWIST ®PBGS INOX,PBGSIT INOXPencil brushes,individual filamenttype, PBU SiC/INOX,PBUIT INOX100-150 HBMACHINABILITY GROUPHARDTC burrZ-ALUTC burrZ-ALU + coatingTC burrZ-ALU PLUSTC burrZ-3PMounted pointsHardness F-ALUMounted pointsHardness MAbrasive spiral bandsGSBCO-COOLCOMBIDISC ®abrasive discsA-COOL, CO-COOL,TX, SiCGrinding oils 412 ALURing wheelsA 24 M SGMounted wheelbrushes, individualfilament type,RBU INOX 0,30,RBUIT INOX 0,30Wheel brushes witharbor hole, individualfilament typeRBU INOXPencil brushes,knotted,SINGLETWIST ®PBGS INOX,PBGSIT INOXPencil brushes,individual filamenttype, PBU SiC/INOX,PBUIT INOX18

Machining ProcessesWeld DressingPOLIVLIES ®flap discs and selfadhesivediscsFibre discsA-COOL,CO-COOLCOMBICLICK ®A-COOL,CO-COOL, SiC,PNER, VRH, VRWGrinding oils412 ALUPOLICLEAN ®discRein<strong>for</strong>cedgrinding wheelsA 24 N SG-ALURein<strong>for</strong>cedgrinding wheelsA46 H SGP-WHISPER-ALUPOLIFAN ®flap discsSG-A-COOLPOLIFAN ®flap discsSGP-A-CURVE-ALUFlaring cupbrush threaded,individual filamenttype, KBU INOXFlaring cupbrush threaded,knotted,KBG INOXWheel brusheswith arborhole/threaded,knotted,RBG INOX,RBGIT INOXWheel brusheswith arborhole/threaded,individual filamenttype, RBG INOXShort beltsA-COOL,CO-COOLLong beltsGrinding oils412 ALURaspsFiles <strong>for</strong> soft metalPLUS ® fileMachinist‘s file C1Milled tooth fileManual brushes<strong>for</strong> precisionmechanics15-60 HBPOLIVLIES ®flap discs and selfadhesivediscsFibre discsA-COOL,CO-COOLCOMBICLICK ®A-COOL,CO-COOL, SiC,PNER, VRH, VRWGrinding oils412 ALUPOLICLEAN ®discRein<strong>for</strong>cedgrinding wheelsA 24 N/O SG-ALURein<strong>for</strong>cedgrinding wheelsA46 H SGP-WHISPER-ALUPOLIFAN ®flap discsSG-A-COOLPOLIFAN ®flap discs SGP-A-CURVE-ALUFlaring cupbrush threaded,individual filamenttype, KBU INOXFlaring cupbrush threaded,knotted,KBG INOXWheel brusheswith arborhole/threaded,knotted,RBG INOX,RBGIT INOXWheel brusheswith arborhole/threaded,individual filamenttype, RBG INOXShort beltsA-COOL,CO-COOLLong beltsGrinding oils412 ALUFiles <strong>for</strong> soft metalPLUS ® fileMachinist‘s file C1Milled tooth fileManual brushes<strong>for</strong> precisionmechanics40-150 HBPOLIVLIES ®flap discs and selfadhesivediscsFibre discsA-COOL,CO-COOLCOMBICLICK ®A-COOL,CO-COOL, SiC,PNER, VRH, VRWGrinding oils412 ALUPOLICLEAN ®discRein<strong>for</strong>cedgrinding wheelsA 24 O SG-ALURein<strong>for</strong>cedgrinding wheelsA46 H SGP-WHISPER-ALUPOLIFAN ®flap discsSG-A-COOLPOLIFAN ®flap discsSGP-A-CURVE-ALUFlaring cup brushthreaded,individual filamenttype, KBU INOXFlaring cupbrush threaded,knotted,KBG INOXWheel brusheswith arborhole/threaded,knotted,RBG INOX,RBGIT INOXWheel brusheswith arborhole/threaded,individual filamenttype, RBG INOXShort beltsA-COOL,CO-COOLLong beltsGrinding oils412 ALUFiles <strong>for</strong> soft metalPLUS ® fileMachinist‘s file C1Milled tooth fileDiamond filesManual brushes<strong>for</strong> precisionmechanics100-150 HB19

Machining ProcessesFine Grinding and FinishingDescription of machining tasks:■■Surface roughing/depolishing■■Levelling and removal ofirregularities■■Removal of oxide skin■■Secondary burr removal■■Cleaning15-60 HBMACHINABILITY GROUPSOFT POLICAP ®POLIROLL ® /POLICO ®Fan grindersZ-COOL, SiC,CO-COOLFlap wheelsINOXCOMBIDISC ®abrasive discsA-COOL, CO-COOLCOMBIDISC ®non-woven discsVRW/VRH/PNERGrinding oils412 ALUPoliflex ®fine grinding toolsPUR/GRPOLINOX ®mounted pointsPNZ/PNL SiCPOLINOX ®ring wheelsPNZ/PNL/PNR/PNG/PNERMounted wheelbrushes, individualfilament type,RBU SiCMounted wheelbrushes, individualfilament type,RBU INOX 0,15,RBUIT INOX 0,15Wheel brushes witharbor hole, individualfilament type,RBU SiC40-150 HBMACHINABILITY GROUPTOUGH POLICAP ®POLIROLL ® /POLICO ®Fan grindersZ-COOL, SiCFlap wheelsINOXCOMBIDISC ®abrasive discsA-COOL, CO-COOLCOMBIDISC ®non-woven discsVRW/VRH/PNERGrinding oils412 ALUPoliflex ®fine grinding toolsGR/TXPOLINOX ®Mounted pointsPNZ/PNL SiCPOLINOX ®ring wheelsPNZ/PNL/PNR/PNG/PNERMounted wheelbrushes, individualfilament type,RBU SiCMounted wheelbrushes, individualfilament type,RBU INOX 0,15,RBUIT INOX 0,15Wheel brushes witharbor hole, individualfilament type,RBU SiC100-150 HBMACHINABILITY GROUPHARD POLICAP ®POLIROLL ® /POLICO ®Fan grindersZ-COOL, SiCFlap wheelsINOXCOMBIDISC ®abrasive discsA-COOL, CO-COOL,COMBIDISC ®non-woven discsVRW/VRH/PNERGrinding oils412 ALUPoliflex ®fine grinding toolsGR/GHR/TXPOLINOX ®mounted pointsPNZ/PNL SiCPOLINOX ®ring wheelsPNZ/PNL/PNR/PNG/PNERMounted wheelbrushes, individualfilament type,RBU SiCMounted wheelbrushes, individualfilament type,RBU INOX 0,15,RBUIT INOX 0,15Wheel brushes witharbor hole,individual filamenttype, RBU SiC20

Machining ProcessesFine Grinding and FinishingPOLIVLIES ®flap discsPOLICLEAN ®discCOMBICLICK ®A-COOL,CO-COOL, SiC,PNER, VRH, VRWGrinding oils412 ALUShort beltsA-COOL, CO-COOLLong beltsCar bodyfiles, specialblade typeAbrasivesheetsManualbrushes <strong>for</strong>precisionmechanicsINOXPOLINOX ®unitized wheelsPNERPOLINOX ®unitized discPNERFibre discsA-COOL,CO-COOLPOLIVLIES ®self-adhesivediscsDisc brushes,individualfilament type,DBUR SiCGrinding oils 412 ALUNon-woven abrasive beltsEconomy rollsNon-woveneconomy rollsPOLIVLIES ®hand pads15-60 HBPOLIVLIES ®flap discsPOLICLEAN ®discPOLINOX ®unitized wheelsPNERPOLINOX ®unitized discPNERFibre discsA-COOL,CO-COOLCOMBICLICK ®A-COOL,CO-COOL, SiC,PNER, VRH,VRWGrinding oils412 ALUPOLIVLIES ®self-adhesivediscsDisc brushes,individualfilament type,DBUR SiCShort beltsA-COOL, CO-COOLLong beltsGrinding oils 412 ALUNon-woven abrasive beltsCar bodyfiles, specialblade typeAbrasivesheetsEconomy rollsNon-woveneconomy rollsPOLIVLIES ®hand padsManualbrushes <strong>for</strong>precisionmechanicsINOX40-150 HBPOLIVLIES ®flap discsPOLICLEAN ®discPOLINOX ®unitized wheelsPNERPOLINOX ®unitized discPNERFibre discsA-COOL,CO-COOLCOMBICLICK ®A-COOL,CO-COOL, SiC,PNER, VRH,VRWGrinding oils412 ALUPOLIVLIES ®self-adhesivediscsDisc brushes,individualfilament type,DBUR SiCShort beltsA-COOL, CO-COOLLong belts ZGrinding oils 412 ALUNon-woven abrasive beltsCar bodyfiles, specialblade typeAbrasivesheetsEconomy rollsNon-woveneconomy rollsPOLIVLIES ®hand padsManualbrushes <strong>for</strong>precisionmechanicsINOX100-150 HB21

Machining ProcessesTexturingDescription of machining tasks:■■Creation of visual effects■■Achieving a homogeneoussurface finish■■Marbling■■Matt finishing, brush matting orsatin finishing■■Removal of surface defectsMACHINABILITY GROUPSOFTMarbling disc holder withnon-woven discsGrinding oils 412 ALU15-60 HBFan grindersZ-COOL, SiC, CO-COOLFlap wheelsPOLIFLAP ® grinding wheelsTexturing toolsPU-STRUCPoliflex ® marbling toolsPOLINOX ® mounted pointsPNZ, PNL, PNRCOMBIDISC ®non-woven discsVRW/VRH/PNERPOLINOX ® ring wheelsPNZ, PNL, PNR, PNG, PNERMACHINABILITY GROUPTOUGHMarbling disc holder withnon-woven discsGrinding oils 412 ALU40-150 HBFan grindersZ-COOL, SiC, CO-COOLFlap wheelsPOLIFLAP ® grinding wheelsTexturing toolsPU-STRUCPoliflex ® marbling toolsPOLINOX ® mounted pointsPNZ,PNL, PNRCOMBIDISC ®non-woven discsVRW/VRH/PNERPOLINOX ® ring wheelsPNZ, PNL, PNR, PNG, PNERMACHINABILITY GROUPHARDMarbling disc holder withnon-woven discsGrinding oils 412 ALU100-150 HBFan grindersZ-COOL, SiC, CO-COOLFlap wheelsPOLIFLAP ® grinding wheelsTexturing toolsPU-STRUCPoliflex ® marbling toolsPOLINOX ® mounted pointsPNZ, PNL, PNRCOMBIDISC ®non-woven discsVRW/VRH/PNERPOLINOX ® ring wheelsPNZ, PNL, PNR, PNG, PNER22

Aluminium Working ProcessesTexturingPOLIVLIES ®flap discsCOMBICLICK ®PNERShort beltsA-COOL, CO-COOLAbrasive sheetsPOLICLEAN ®discCOMBICLICK ®non-woven discsVRH, VRWLong beltsPOLIVLIES ®hand padsPOLINOX ®unitized wheelsPNERPOLINOX ®unitized discPNERPOLIVLIES ®self-adhesivediscsGrinding oils 412 ALUNon-woven abrasive beltsNon-woven economy rolls15-60 HBPOLIVLIES ®flap discsCOMBICLICK ®PNERShort beltsA-COOL, CO-COOLAbrasive sheetsPOLICLEAN ®discCOMBICLICK ®non-woven discsVRH, VRWLong beltsPOLIVLIES ®hand padsPOLINOX ®unitized wheelsPNERPOLINOX ®unitized discPNERPOLIVLIES ®self-adhesivediscsGrinding oils 412 ALUNon-woven abrasive beltsNon-woven economy rolls40-150 HBPOLIVLIES ®flap discsCOMBICLICK ®PNERShort beltsA-COOL, CO-COOLAbrasive sheetsPOLICLEAN ®discCOMBICLICK ®non-woven discsVRH, VRWLong beltsPOLIVLIES ®hand padsPOLINOX ®unitized wheelsPNERPOLINOX ®unitized discPNERPOLIVLIES ®self-adhesivediscsGrinding oils 412 ALUNon-woven abrasive beltsNon-woven economy rolls100-150 HB23

Machining ProcessesPolishingDescription of machining tasks:■■Polishing small surface areas■■High-gloss polishingMACHINABILITY GROUPSOFTCloth ringsPolishingpaste barsFelt flap discsShort beltsFelt typeFelt pointsGrindingcompoundsCOMBICLICK ®felt discsPolishing pastebars15-60 HBFelt fangrindersPolishing pastebarsGrindingcompoundsFelt wheelsGrindingcompoundsCOMBIDISC ®felt discsMACHINABILITY GROUPTOUGHCloth ringsPolishingpaste barsFelt flap discsShort beltsFelt typeFelt pointsGrindingcompoundsCOMBICLICK ®felt discsPolishing pastebars40-150 HBFelt fangrindersFelt wheelsPolishing pastebarsGrindingcompoundsGrindingcompoundsCOMBIDISC ®felt discsMACHINABILITY GROUPHARDCloth ringsPolishingpaste barsFelt flap discsShort beltsFelt typeFelt pointsGrindingcompoundsCOMBICLICK ®felt discsPolishing pastebars100-150 HBFelt fangrindersFelt wheelsPolishing pastebarsGrindingcompoundsGrindingcompoundsCOMBIDISC ®felt discs24

<strong>PFERD</strong> <strong>Tools</strong> <strong>for</strong> <strong>Use</strong> on AluminiumTable of ContentsPageCatalogue 201Files and Rasps 26Catalogue 202Burrs27-28Catalogue 203Mounted Points29Catalogue 204Fine Grinding and Polishing <strong>Tools</strong>30-31Catalogue 205Diamond and CBN <strong>Tools</strong>26Catalogue 206Grinding and Cut-Off Wheels32-34Catalogue 208Industrial Power Brushes35Catalogue 209Tool Drives3625

<strong>PFERD</strong> <strong>Tools</strong> – Catalogues 201-209Catalogues 201 and 205 – Files<strong>PFERD</strong> files are suitable <strong>for</strong> deburring, chamfering, rough filing and smoothingwork on aluminium and aluminium alloys. Tool loading problems are preventedby a tooth geometry adapted specifically to the requirements associated withworking soft, sticky materials. As a result, minimum ef<strong>for</strong>t is needed to achieve ahigh-grade surface finish.Machinability group SOFTRaspsDeveloped originally <strong>for</strong> woodworking applications,these tools also give excellent results on aluminium.Machinability group SOFT, TOUGH and HARD (Hardness: 15-150 HB)Files <strong>for</strong> soft metalParticularly suitable <strong>for</strong> deburring, chamfering,roughing and smoothing work on soft, sticky materials.<strong>PFERD</strong> PLUS ® filesFor general use such as rough filing, smoothing and deburring.Machinist’s files – Cut 1Perfect <strong>for</strong> deburring.Car body files (special blade type)For producing very good, scratch-free surfaces.Milled tooth filesThese files ensure very high stock removal.Machinability group HARDDiamond files (Catalogue 205)Particularly well suited <strong>for</strong> deburring.Products made to orderFiles can be manufactured to specific application needs by special arrangement.NoteFor further in<strong>for</strong>mation, please referto our <strong>PFERD</strong> Tool Manual, Catalogues201 and 205.Files201Diamond and CBN <strong>Tools</strong>205Recommendations <strong>for</strong> useLoaded files can be cleaned using our HBF 10 file brush.26

<strong>PFERD</strong> <strong>Tools</strong> – Catalogues 201-209Catalogue 202 – BurrsTungsten carbide burrsThese tungsten carbide burrs give excellent results in aluminium work such as welddressing, fettling of castings, deburring, chamfering and geometry adjustments.A large number of geometrical shapes and dimensions (3-16 mm dia.), two cutsand a coating developed specifically <strong>for</strong> this material are available to meet variousneeds in machinability groups SOFT, TOUGH and harD.Our ALU and ALU PLUS cuts reflect the most recent standards of technology.Developed specifically <strong>for</strong> use on aluminium, their geometries ensure optimummachining results at high cutting speeds of up to 1,100 m/min.TC burrs with ALU cutTC burrs with ALU PLUS cutTC burrs with HC-NFE coatingALU cutVc 600-1,100 m/minAn optimum tooth geometry ensuresgood chip removal. Tooth base loading isprevented, even on sticky materials. For usein machinability groups SOFT, TOUGH andharD.Vc 450-700 m/minPreferable <strong>for</strong> coarse milling of aluminiumalloys in machinability groups TOUGH andharD, as well as <strong>for</strong> non-ferrous metals ingeneral. The special tooth geometry ensureshigh stock removal.Vc 600-1,100 m/minThe tool of choice <strong>for</strong> long-chip, stickynon-ferrous metals in machinability groupsSOFT, TOUGH and harD. Improvedfriction and sliding properties reduce the<strong>for</strong>mation of built-up edges. High stockremoval and durability are the hallmarks ofthis range.HSS rotary cuttersThanks to their special tooth geometry and close tolerances, high-speed steel(HSS) rotary cutters are particularly suitable <strong>for</strong> deburring, chamfering, fettling andgeometry adjustment work on aluminium parts, where they produce an enhancedsurface quality. HSS rotary cutters with ALU cut can be used in numerous shapesand dimensions.HSS rotary cutters with ALU cut and with our special cut <strong>for</strong> light alloysguarantee cost-efficient results and are also ideal <strong>for</strong> use on materials inmachinability groups SOFT and TOUGH when working with a low-poweredmachine in the low RPM range.HSS rotary cutter with ALU cutVc = 300 m/minAn optimum tooth geometry ensures goodchip removal.Recommendations <strong>for</strong> useHSS rotary cutter with special cut <strong>for</strong>light alloysVc = 300 m/minParticularly suitable <strong>for</strong> coarse deburring andfettling work on light alloy components andcastings.■■The cost-efficiency of burrs and rotary cutters is contingent on an adequatepower output and appropriate RPM of the machine.To select the right cut <strong>for</strong> a given application, note the following rule:The harder and more brittle the material, the finer the cut should be.■■The coating of tungsten carbide burrs prevents tool loading problems undermost application conditions, even with very sticky alloys. With uncoated burrs,grinding oil can be used to prevent tooth bases from clogging up too quickly.Products made to orderIf our extensive Catalogue rangeshould not include what you need, wecan produce custom products tailoredto your requirements in terms of■■tooth specifications■■shank length■■diameter.Especially in high-volume manufacturing,milling operations areincreasingly robotized. For suchapplications <strong>PFERD</strong> offers burrs androtary cutters providing still closertolerances and constant stock removal.Please do not hesitate to contact us.The application technicians in ourtechnical customer support departmentwill be glad to help.27

<strong>PFERD</strong> <strong>Tools</strong> – Catalogues 201-209Catalogue 202 – Hole Saws and Hole CuttersHSS hole sawsHSS hole saws are excellent <strong>for</strong> producing accurate cut-outs fast. Their high-gradeHSS tooth set guarantees cost-efficient per<strong>for</strong>mance, particularly on thin-walledaluminium components in the SOFT and TOUGH machinability groups. A longservice life and burr-free edges are achieved with these tools.HSS hole saws sets<strong>PFERD</strong> offers five different sets of holesaws in the most common diametersused by craftsmen, plumbers, fittersand electricians (Germany andinternational).TC hole cuttersThanks to their high-grade tungsten carbide tips, these TC hole cutters provideoutstanding results and superior cost-efficiency on aluminium alloys in the SOFT,TOUGH and harD machinability groups. Two versions (flat, deep) facilitatemachining on diverse workpieces, including curved surfaces.8 mmTC hole cutters are supplied in two heights:■■8 mm (flat version) <strong>for</strong> use on sheet metal and flat material,available in various diameters from 16 to 105 mm.■■35 mm (deep version) <strong>for</strong> use on pipes and curved surfaces,available in various diameters from 16 to 60 mm.35 mmRecommendation <strong>for</strong> use■■To reduce cutting <strong>for</strong>ces, paraffin should be used when sawing aluminium.This will ensure a smoother operation of the tool while also extending its servicelife.NoteFor furtherin<strong>for</strong>mation, pleaserefer to our <strong>PFERD</strong>Tool Manual,Catalogue 202.Burrs20228

203 I 1<strong>PFERD</strong> <strong>Tools</strong> – Catalogues 201-209Catalogue 203 – Mounted PointsMounted points are suitable <strong>for</strong> pre-grinding, deburring, chamfering, fettling andfine-grinding aluminium and associated alloys in the SOFT, TOUGH and harDmachinability groups. Since the spaces between grit particles (chip clearance) arevery small on these tools, they are particularly susceptible to loading. <strong>PFERD</strong> hasthere<strong>for</strong>e developed a special bond which ensures unsurpassed stock removal overthe entire tool life even on soft, sticky materials.Mounted points – hardness F-ALUThese tools are made with a vitrified bond and green silicon carbide. A specialtreatment prevents loading on sticky materials. The hardness F-ALU denotes oneof the softer and most aggressive bonds available <strong>for</strong> mounted points.Hardness F-ALUProducts made to orderBy special arrangement we can produce mounted points adapted specifically toyour application needs, e.g.■■other dimensions and shapes■■different grit sizes and abrasive types■■bespoke grain mixtures■■special shank diameters and lengths.In addition, <strong>PFERD</strong> supplies impregnated special product versions in hardnessgrades M and L <strong>for</strong> use on aluminium. These tools are specially designed toprevent loading on particularly sticky aluminium materials (machinability groupSOFT).Hardness MHardness LRecommendations <strong>for</strong> use■■Mounted points of hardness grade F-ALU per<strong>for</strong>m best at a recommendedperipheral speed of 20-40 m/s.■■The use of grease or grinding oil is recommended.■■Mounted points are used with flexible shafts or (electric or air-powered)straight grinders.Safety notes■■All mounted points in the <strong>PFERD</strong> range are approved <strong>for</strong> a maximum peripheralspeed of 50 m/s. Applicable RPM limits <strong>for</strong> various shank lengths and shankdiameters are defined in EN 12413. It is absolutely necessary to comply withthese maximum values to prevent the tool shank from buckling in use.NoteFor furtherin<strong>for</strong>mation, pleaserefer to our <strong>PFERD</strong>Tool Manual,Catalogue 203.Mounted PointsMounted Points20320329

<strong>PFERD</strong> <strong>Tools</strong> – Catalogues 201-209Catalogue 204 – Grinding and Polishing <strong>Tools</strong>Fine grinding and polishing tools are suitable <strong>for</strong> pre-grinding, deburring,chamfering, fettling, fine grinding, texturing and polishing operations onaluminium and its alloys in machinability groups SOFT, TOUGH and harD.The tools which are suitable <strong>for</strong> machining aluminium can be summarized ingroups:■■Coated abrasive tools■■Non-woven abrasive tools■■Bonded abrasive tools■■Polishing toolsCoated abrasive toolsin Catalogue 204:■■Abrasive spiral bands■■POLIROLL ® , POLICO ®■■Fan grinders, flap wheelsand flap rolls■■COMBIDISC ® grinding discs■■Special tools■■Short and long belts■■Economy rolls andsheet material■■Fibre discs andvelcro-backed abrasive discs■■COMBICLICK ® fibre discs■■Grinding oil 412 ALUCoated abrasive toolsCoated abrasive tools, with a cover bond actively supporting the grinding process,are suitable <strong>for</strong> use on aluminium surfaces. The additional cover layer cools theworkpiece and prevents aluminium from adhering to the spaces between abrasiveparticles. Silicon carbide (SiC) is highly suitable <strong>for</strong> use on aluminium due to theshape of its grains. Depending on grit size, coated abrasive tools can provide highremoval rates (e.g. during chamfering with 36 grit fibre discs) or a very fine surfacefinish if a fine-grained abrasive is used (e.g. pre-polishing with a 320 grit fangrinder).The service life of coated abrasive tools can be greatly extended through the useof our grinding oil 412 ALU. This oil prevents chip particles from adhering to theabrasive surface and thereby prevents loading problems.Activegrinding layerStructure of coated abrasiveproductsBackingmaterialBasic bond Top bond AbrasiveparticlesNon-woven abrasive toolsin Catalogue 204:■■COMBIDISC ® non-woven discs■■COMBICLICK ® non-woven discs■■POLINOX ® mounted points,wheels and drums■■Special tools■■POLIVLIES ® discs■■POLIVLIES ® self-adhesive discs■■POLICLEAN ® tools■■Short belts, non-woven typesNon-woven abrasive toolsThe very open structure of the non-woven abrasive material prevents loadingand heat build-up during grinding. Non-woven abrasive tools are excellent <strong>for</strong>producing fine and ultra-fine finishes, light cleaning, removing oxide layers, andcreating surface textures.Structure ofnon-wovenabrasiveAbrasive gritSynthetic fibresResin30

<strong>PFERD</strong> <strong>Tools</strong> – Catalogues 201-209Catalogue 204 – Grinding and Polishing <strong>Tools</strong>Recommendations <strong>for</strong> use:■■In aluminium machining applications, coated abrasive tools per<strong>for</strong>m best atthe recommended peripheral speed of 20-40 m/s.■■Non-woven abrasive tools give best results on aluminium when used at therecommended peripheral speed of 10-20 m/s.■■Polishing operations should be carried out at peripheral speedsof 5-10 m/s.■■The use of a grinding oil is recommended as it protects the tool from prematurewear.■■Suitable power sources are flexible shaft drives or (electric or air-powered)straight grinders.Bonded abrasive toolsBonded abrasive tools give outstandingper<strong>for</strong>mance in fine grinding andpre-polishing jobs, e.g. on aluminiummoulds <strong>for</strong> plastic injection moulding(blow moulding of PET bottles).Fine grinding tools adapted to eachapplication are available in the mostdiverse shapes and a broad rangeof grit types, grit sizes and hardnessgrades.Bonded abrasive toolsin Catalogue 204:■■Poliflex ® mounted points■■Poliflex ® abrasive discs■■Poliflex ® blocksPolishing tools<strong>PFERD</strong> offers an extensive range ofaluminium polishing tools in diversediameters, hardness grades, gritsizes, types and shapes, as well asthe associated polishing pastes/compounds.Products made to orderIf our extensive Catalogue range should not include what you need, we canproduce bespoke solutions <strong>for</strong> your application needs, e.g.■■other dimensions and shapes■■different grit sizes and abrasive types■■bespoke grain mixtures■■special shank diameters and lengths.Please talk to our sales representatives. The application technicians in ourtechnical customer support department will be glad to help.Bonded abrasive toolsin Catalogue 204:■■Felt points and discs■■COMBIDISC ® felt discs■■COMBICLICK ® felt discs■■Felt flap discs■■Short abrasive belts – felt type■■Cloth rings■■Grinding compounds■■Polishing pastesNotesAll <strong>PFERD</strong> tools aremanufactured andtested to applicablesafety standards.For furtherin<strong>for</strong>mation, pleaserefer to our <strong>PFERD</strong>Tool Manual,Catalogue 204.Fine Grinding and Polishing <strong>Tools</strong>20431

<strong>PFERD</strong> <strong>Tools</strong> – Catalogues 201-209Catalogue 206 – Cut-Off WheelsFor cutting aluminium and its alloys, <strong>PFERD</strong> has developed a range of specialcut-off wheels. These products contain no fillers which might leave undesirableresidue on the workpiece. The surfaces can there<strong>for</strong>e be welded immediatelyafterwards.They can be used on angle grinders of all output categories.Cut-off wheels – hardness N-ALUCut-off wheels of hardness grade N-ALU provide aggressive stock removal andare not susceptible to loading problems on aluminium workpieces in machinabilitygroups SOFT, TOUGH and harD. They are laminated on both sides with asilver-coated labelling film which prevents metal adhesion and clogging of theabrasive material.Products made to orderBy special arrangement, cut-off wheels <strong>for</strong> use on aluminium can be manufacturedto specific application needs.Special specifications may include, e.g.■■non-standard sizes and widths■■different grit types, e.g. SiC.Recommendations <strong>for</strong> use:■■1.0 mm disc width: especially <strong>for</strong> sheet metal■■1.6 mm disc width: <strong>for</strong> thin-walled workpieces■■2.4 mm disc width: <strong>for</strong> general cut-off work■■2.9 mm disc width: <strong>for</strong> maximum tool life and high lateral stabilitySafety notesAbrasive manufacturers, machine producers and users contribute equally toensuring grinding safety. All <strong>PFERD</strong> tools are built to meet applicable safetyrequirements. However, the ultimate responsibility <strong>for</strong> the correct handling andsafe operation of power tools and abrasive products rests with the user.In particular, the following rules apply:■■The maximum operating speed [m/s] stated on the product labelmust not be exceeded.■■The use of flanges having two different diameters is to be avoided.32

<strong>PFERD</strong> <strong>Tools</strong> – Catalogues 201-209Catalogue 206 – Rein<strong>for</strong>ced Grinding WheelsFor grinding work on aluminium and aluminium alloys, <strong>PFERD</strong> has developedspecial rein<strong>for</strong>ced grinding wheels which provide high stock removal and will notload even when used on soft alloys.Rein<strong>for</strong>ced grinding wheels – hardness N-ALUThese tools deliver outstanding stock removal even at low contact pressure, thuseffectively preventing loading problems on alloys in machinability groups SOFTand TOUGH. Rein<strong>for</strong>ced grinding wheels made by <strong>PFERD</strong> are suitable <strong>for</strong> usewith angle grinders of all output categories. They contain no fillers which mightleave undesirable residue on the workpiece. Machined surfaces can there<strong>for</strong>e bewelded right away.Rein<strong>for</strong>ced grinding wheels – hardness O-ALUSuitable <strong>for</strong> alloys in machinability groups TOUGH and harD.Rein<strong>for</strong>ced grinding wheels – hardness H-ALUThe rein<strong>for</strong>ced grinding wheel WHISPER ALU is an innovative high-per<strong>for</strong>mancetool <strong>for</strong> unusually high demands on stock removal, surface quality and workingcom<strong>for</strong>t. Very soft, smooth grinding characteristic and high degree of workingcom<strong>for</strong>t with low vibration, dust and noise levels. Very high machining capacityfrom the very start.Suitable <strong>for</strong> alloys in machinability groups SOFT, TOUGH, harD.Products made to orderRein<strong>for</strong>ced grinding wheels <strong>for</strong> use on aluminium can be manufactured to yourspecific application needs by special arrangement.Special specifications may include, e.g.■■non-standard sizes and widths■■different grit types, e.g. SiC.Recommendations <strong>for</strong> use■■7.2 mm disc width: suitable <strong>for</strong> general-purpose grinding.Safety notes■■The maximum operating speed [m/s] stated on the product label must not beexceeded.■■In some countries, 178/230 mm dia. rein<strong>for</strong>ced grinding wheels are subject tospecial regulations regarding the use of special flanges and/or adapter systems.33

<strong>PFERD</strong> <strong>Tools</strong> – Catalogues 201-209Catalogue 206 – POLIFAN ® Flap DiscsFor use on aluminium, POLIFAN ® flap discs with an active grinding layer coveringthe grit on each flap are particularly suitable. This feature prevents aluminiumchips from adhering to the abrasive material.The service life of coated abrasive products can be extended significantly throughthe use of our grinding oil 412 ALU (see catalogue 204). Adding this oil will helpavoid tool loading and the adhesion of chip particles.POLIFAN ® flap discs – SG-A-COOLDesigned <strong>for</strong> outstanding metal removal rates and low heat build-up when usedon variable-speed angle grinders, these tools are ideal <strong>for</strong> work on sheet metaland thin-walled sections in machinability groups SOFT and TOUGH.POLIFAN ® flap discs – SG-ASuitable <strong>for</strong> general-purpose grinding on weld seams and edges of materials inmachinability groups TOUGH and harD.POLIFAN ® flap discs – SGP-A-CURVE-ALUInnovative grinding tool <strong>for</strong> the precise, optimum grinding out of fillet welds and<strong>for</strong> contour grinding. Suitable <strong>for</strong> workpieces of the machinability groups SOFT,TOUGH and harD.POLIFAN ® flap discs – SGP-CO-COOLThese special-purpose tools meet the most exacting grinding standards, deliveringcool grinding per<strong>for</strong>mance, aggressive stock removal at minimum contactpressure, plus outstanding cost-efficiency. They are suitable <strong>for</strong> workpieces inmachinability groups TOUGH and harD.Products made to orderUpon request, POLIFAN ® flap discs can be produced to your specific applicationrequirements.Custom specifications may include, e.g.■■non-standard dimensions■■different grit types, e.g. SiC.NotesRecommendations <strong>for</strong> use■■Recommended <strong>for</strong> use in all three machinability groups.■■Designed preferably <strong>for</strong> use in the lower RPM range of variable-speed anglegrinders.■■The use of grinding oil is recommended as a safeguard against premature wear.Safety note■■The maximum operating speed [m/s] stated on the product label must not beexceeded.All <strong>PFERD</strong> tools aremanufactured andtested to applicablesafety standards.For furtherin<strong>for</strong>mation, pleaserefer to our <strong>PFERD</strong>Tool Manual,Catalogue 206.Grinding and Cut-Off Wheels20634

208 I<strong>PFERD</strong> <strong>Tools</strong> – Catalogues 201-209Catalogue 208 – Industrial Power BrushesThe flexibility benefits of industrial power brushes become particularly evident whenit comes to machining aluminium. A brush can deburr workpieces and conditionsurfaces without significantly interfering with the material’s dimensional accuracy.This holds true both on handheld machines and in stationary or robotized use.Industrial power brushes <strong>for</strong> use on aluminium are particularly well suited <strong>for</strong> finedeburring work on materials in machinability groups SOFT, TOUGH and harD.SiC fill brushesAbrasive grit is encapsulated in the flexible nylon filaments. New grit becomesprogressively exposed as the carrier material wears down so that the brush retainsits constant aggressiveness. Available in different grit sizes <strong>for</strong> diverse applications.INOX fill brushesThese brushes are suitable <strong>for</strong> removing the oxide skin from aluminium surfaces,e.g., in preparation of welding. All INOX brushes made by <strong>PFERD</strong> are supplied ina degreased state and will there<strong>for</strong>e not leave any corrosive residue or <strong>for</strong>eignmatter on the workpiece.Brushes INOX-TOTAL typeWe offer a range of <strong>PFERD</strong> brushes in the “INOX TOTAL” design <strong>for</strong> the mostdemanding of operating conditions. These brushes have been designed especially<strong>for</strong> machining stainless steel (INOX), and stand out due to the fact that all brushparts are made of stainless steel of the quality 1.4310 (V2A) and thus guaranteeoptimum corrosion protection.SiCINOX/INOX-TOTALIndustrial Power Brushesin Catalogue 208:■■Wheel brushes with arbor hole■■Mounted wheel brushes■■Cup brushes with threaded hole■■Disc brushes■■Mounted cup brushes■■Mounted pencil brushes■■Interior brushes with threaded hole■■Scratch brushesProducts made to orderIf our extensive Catalogue rangeshould not include what you need,we can customize products to yourapplication in terms of filament gauge,grit size, diameter, and fill width/length.Please talk to our sales representativesor contact the application techniciansin our technical customer supportdepartment. They will be glad to help!Schematic view SiC fillAbrasive grit is en capsulatedin nylon filaments.Fresh gritgets progressivelyexposed.Recommendations <strong>for</strong> use■■To avoid corrosion, do not work with brushes previously used on steel, copperor other metals.■■For “fine” deburring work on complex components, use an SiC-filled brush.■■The use of SiC-filled brushes with longer filaments is recommended <strong>for</strong> deburringcomplex aluminium parts.■■An INOX brush should be preferred <strong>for</strong> “heavy” burr removal.■■INOX brushes used on aluminium should have the smallest filament diameterconsistent with application.■■For applications which place particular demands on high brush aggressiveness,disc brushes with rectangular SiC fillings (REC) should be used.■■The above-mentioned <strong>PFERD</strong> brushes will give best results on aluminium whenused at the following recommended cutting speeds:- Wheel brushes and flaring cup brushes with SiC fill 10-20 m/s- Wheel brushes and flaring cup brushes with INOX fill 15-30 m/s- Pencil brushes 5-10 m/s- Cup brushes 25-35 m/s- Disc brushes 10-20 m/sNotesAll <strong>PFERD</strong> tools aremanufactured andtested to applicablesafety standards.Industrial Power BrushesAccessoriesFor furtherPlatzhalterfür Titelin<strong>for</strong>mation, pleaserefer to our <strong>PFERD</strong>Tool Manual,1Catalogue 208.20820835

209 I<strong>PFERD</strong> <strong>Tools</strong> – Catalogues 201-209Catalogue 209 – Power <strong>Tools</strong><strong>PFERD</strong> offers an extensive machine range adapted to the per<strong>for</strong>mance, RPM andpower specifications of <strong>PFERD</strong> tools. These machines are engineered to optimizethe cost-efficiency of our products and comply with the applicable version of theEC Machinery Directive 2006/42/EC (Machinery Directive GPSGV).Light finishing, grinding, polishing and deburring work requires less power outputbut a lighter, handier machine. Regular milling, grinding, coarse machining anddeburring jobs (especially under heavy-duty conditions), in turn, call <strong>for</strong> the use ofpowerful and rugged machines.Air grindersTurbine-type, straight, angle and beltgrindersSpeed range:3,500-100,000 RPMPower rating:75-1,000 WRecommendations <strong>for</strong> use■■Particularly suitable, given that airmotors produce no sparks.■■Preferable <strong>for</strong> tools requiringspeeds over 36,000 RPM■■For tools which can only be usedin one RPM range.Electric grindersStraight, angle, drum, belt and filletweld grindersSpeed range:750-33,000 RPMPower rating:500-1,530 WRecommendations <strong>for</strong> use■■<strong>Use</strong> only with a very effectiveextraction system, e.g. with a wetseparator. The sparks producedby the carbon brushes may ignitealuminium dust.■■Electric machines should becleaned with compressed air afteruse.Flexible shafts and drive unitsFlexible shaft drives powered byuniversal or three-phase motors.Speed range:0-36,000 RPMPower rating:500-6,100 WRecommendations <strong>for</strong> use■■Mount the drive motor outsidethe grinding booth or dust emissionsite.■■Virtually all <strong>PFERD</strong> tools describedin this publication can be used.05/2013 Subject to technical modifications. Printed in Germany.817 117Workplace design recommendations■■The ideal workplace <strong>for</strong> machining aluminium workpieces is equipped withan effective extraction system and, possibly, wet extraction equipment.The explosion or fire hazard resulting from spark <strong>for</strong>mation increases withthe concentration of aluminium particles in the air. Special caution must beexercised when working aluminium materials which contain magnesium;their dusts may be highly explosive. Spark-producing power units constitute ahazard. However, sparks may also result from tool-to-material contact.■■Classify work environments according to the codes of the Workmen’sCompensation Insurance Association with regard to the prevention of dustfires and dust explosions, then select power units in accordance with thisclassification.Safety noteSelect machines in accordance withthe classification of your workplace asdefined in BGR 109, “Prevention ofDust Fires and Dust Explosions duringAluminium Grinding, Brushing andPolishing”, a publication of the GermanAssociation of Workmen’s CompensationInsurers.Tool DrivesTool Drives209NoteFor more detailedin<strong>for</strong>mation onpower tools andPlatzhaltermotor units <strong>for</strong> toolfür Titeldrives, please referto our Tool Manual,Catalogue 209.12094007220 8 6186836www.pferd.com · info@pferd.com<strong>PFERD</strong> quality certified according to EN ISO 9001.