How to Choose the Right Mounted Points for Your Project

Mounted points are small, versatile abrasive tools used in various industrial applications, including grinding, deburring, and finishing. These tools are essential for achieving precision and efficiency in tasks that require detailed work on different materials. Selecting the right mounted points is crucial to ensure the quality and efficiency of your projects, as the wrong choice can lead to suboptimal results and increased wear on the tools.

Mounted Points from Kayson Green

1. Mounted Points for Machining Tool Steels
   High-performance mounted points, specifically designed for machining tool steels, to provide long tool life and high stock removal performance.
2. Mounted Points for Machining Cast Materials
   Ideal for machining cast materials, offering effective rough processing and high stock removal.
3. Bonded Polishing
   Useful for applications requiring fine finishing.

Understanding Mounted Points

Mounted points consist of abrasive grains bonded together and attached to a mandrel. They come in various shapes, sizes, and materials, making them suitable for a wide range of applications. The key to choosing the right mounted point lies in understanding the material you are working on, the shape of the mounted point, and the specific application.

Material Considerations

The type of material you are working on significantly influences the choice of mounted points. Different materials require specific abrasive grains to achieve the best results:

1. Aluminum Oxide
   Ideal for ferrous metals such as steel and iron. It offers durability and efficient material removal.
2. Silicon Carbide
   Best suited for non-ferrous metals, ceramics, and glass. It provides a sharper cut and is excellent for hard, brittle materials.
3. Ceramic
   Used for high-performance applications, ceramic abrasives offer a longer lifespan and are suitable for tough materials like stainless steel.
4. Diamond and CBN (Cubic Boron Nitride)
   These superabrasives are used for extremely hard materials, including carbide and hardened steel.

Shape and Size

The shape and size of the mounted point significantly affect its performance and suitability for specific tasks:

1. Cylindrical
   Ideal for surface grinding and finishing flat surfaces.
2. Conical
   Suitable for deburring and working on angled surfaces.
3. Ball
   Perfect for precision work and finishing concave surfaces.
4. Bullet
   Great for detailed work and accessing tight spaces.

Choosing the right shape ensures that the mounted point can effectively reach and work on the desired area. The size should match the scale of the task, with smaller points being more manoeuvrable for intricate work and larger points being more efficient for bulk material removal.

Grit Size

Grit size impacts the finish and material removal rate:

1. Coarse Grits (Lower Numbers)
   Suitable for heavy material removal but may leave a rougher surface finish.
2. Fine Grits (Higher Numbers)
   Ideal for finishing and polishing, providing a smoother surface but removing material more slowly.

Selecting the appropriate grit size depends on the specific requirements of your application. For example, use coarser grits for initial grinding and finer grits for final finishing. 

Bond Type

Different bond types offer various advantages and disadvantages:

1. Vitrified Bonds
   Provide a strong, durable bond that can withstand high temperatures and heavy loads. They are ideal for precision grinding.
2. Resin Bonds
   Offer flexibility and are suitable for applications requiring a smoother finish. They are less durable than vitrified bonds but can handle a wider range of materials.
3. Rubber Bonds
   Provide excellent control and are used for fine finishing and polishing.
4. Metal Bonds
   Used mainly for superabrasives, offering high strength and durability.

RPM and Machine Compatibility

Ensuring that the mounted point is compatible with the operating speed and specifications of the grinding machine is essential for safety and performance:

1. RPM Rating
   Each mounted point has a maximum recommended RPM. Exceeding this can lead to premature wear, reduced effectiveness, and potential safety hazards.
2. Machine Specifications
   Match the mounted point to the machine’s capabilities, including the spindle size and speed range. Using incompatible tools can result in poor performance and an increased risk of accidents.

Common Applications for Mounted Points

Mounted points are versatile tools used in a variety of applications across different industries. Here are some common uses:

1. Grinding
   Surface grinding for smoothing and finishing flat surfaces, and cylindrical grinding for the outer surface of cylindrical objects.
2. Deburring
   Edge deburring removes sharp edges and burrs, and fine deburring for intricate parts.
3. Polishing
   Surface polishing for a smooth, reflective finish, and detail polishing for small, hard-to-reach areas.
4. Re-grinding Transitions
   Refines or smooths transitions between surfaces, frequently used in the automotive and aerospace industries.
5. Groove Grinding
   Commonly utilized for forming or enhancing grooves in metal and various other materials.
6. Tool and Die Work
   Precision grinding for detailed work, ensuring precise dimensions and finishes.
7. Mould and Pattern Making
   Detail work for fine detail in moulds and patterns.
8. Weld Cleaning
   Post-weld cleaning to remove slag and smooth weld seams.
9. Sharpening
   Maintains the sharpness of cutting tools.
10. Material Removal
    Roughing to remove excess material quickly during initial shaping or finishing.

Maintenance Tips for Mounted Points

By following these suggested maintenance tips for your mounted points, you can extend their lifespan.

1. Inspect your mounted points regularly
   Check for Wear and tear. Signs of this are uneven surfaces, cracks or chips. Replace any damaged points to maintain efficiency and safety. Additionally, monitor the performance of your mounted points. Paying attention to changes in performance such as ineffective cutting or increased vibration as this is a sign the point needs to be replaced.
2. Store your mounted points properly
   Store your mounted points in a clean, dry environment. Moisture can cause rust and degradation of the bonding material. Keep them organised by type and size so you can easily find the right tool for the job. This also helps prevent damage to the points.
3. Keep your mounted points clean
   Remove debris and residue after each use and avoid cross-contamination by thoroughly cleaning mounted points used on different materials. You can use a brush or compressed air to achieve this.
4. Use them correctly
   Follow the manufacturer’s guidelines regarding speed, pressure, and application. Avoid overheating as excessive heat can damage both the mounted point and the workpiece. Use appropriate cooling methods for your project, such as coolant or water to keep the temperatures down.

Safety Tips for Using Mounted Points

Keeping yourself and others safe while using mounted points is extremely important.

Personal Protective Equipment (PPE)

1. Eye Protection
   Keep your peepers protected with safety goggles. Flying debris is a risk, and your eyes must be shielded to avoid a nasty accident.
2. Hearing Protection
   Protect your hearing by using ear plugs or earmuffs to avoid causing long-term and lasting damage to your hearing.
3. Respiratory Protection
   Wearing a dust mask or respirator will help you avoid inhaling harmful particles while working.
4. Hand protection
   Wear suitable gloves to protect your hands from sharp edges and abrasive materials.

Machine Safety

1. Secure Mounting
   Ensure that the mounted point is securely attached to the tool to prevent it from coming loose during operation.
2. Check RPM Ratings
   Verify that the mounted point’s RPM rating matches the operating speed of the machine. Exceeding the recommended speed can cause the mounted point to break.
3. Guarding
   Use machine guards to protect against accidental contact with the rotating mounted point.

Operation Safety

1. Stable Work Environment
   Ensure that the workpiece is securely clamped and that the work area is stable to prevent accidents.
2. Avoid Distractions
   Stay focused on the task at hand and avoid distractions that could lead to mistakes or accidents.
3. Proper Technique
   Use the correct technique for the task, applying consistent pressure and avoiding excessive force that could damage the mounted point or the workpiece.

Be prepared for an Emergency

1. First aid kit
   Keep a fully stocked first aid kit to hand in case of accidents. Regularly check the items in it are in date by keeping an inventory of its contents.
2. Emergency procedures
   Make sure everyone understand the emergency protocols, especially how to shut off machinery quickly and how to respond to injuries.

Common Mistakes to Avoid When Using Mounted Points

Avoiding common mistakes when selecting mounted points can save time, money, and ensure better results. Here are some pitfalls to watch out for:

1. Choosing the Wrong Abrasive Material
   Ensure the abrasive material matches the workpiece.
2. Ignoring the Shape Requirements
   Use the correct shape for the task.
3. Overlooking Grit Size
   Match the grit size to the task requirements.
4. Not Considering the Speed Rating
   Stay within the recommended RPM.
5. Using Worn-Out Mounted Points
   Regularly inspect and replace worn points.
6. Incorrect Mounting
   Ensure secure and correct attachment to the tool.
7. Neglecting Safety Measures
   Always use appropriate PPE.

By considering these factors and avoiding common mistakes, you can select the most suitable mounted points for your project, ensuring efficiency, safety, and high-quality results.