The biggest difference between belt grinders and other types of grinding machines: Belt grinders use a fast-moving coarse belt, similar to sand paper, to contour metals. Other types of grinding machines, though, typical use a metal blade or grinding bit to remove material.

Belt Grinders vs. Belt Sanders

There’s some common confusion about the difference between these two devices. They both work in a similar manner. The motor powers a fast-moving stationary belt, which the operator then engages the materials to make them smooth and add contour. But that’s where the similarities stop.

Of the differences, belt grinders are typically designed to be used with metal workpieces, whereas belt sanders are used primarily with wood. Additionally, the differences include:

• Belt grinders tend to have faster belt speeds, from 70 to 135 feet per second. This is needed when working with metals.
• Their motors have more horsepower.
• And they’re designed to be used with flat or rubber platens.

Due to the grinders greater power output and faster belt speeds, these machines tend to have the ability to remove material from the workpiece and smooth metals. Using a belt sander with metals will result in damage to the machine and/or undesirable results.

Belt Grinder Applications

In metal working, belt grinders are used for a variety of tasks. There are three main tasks though:

• Deburring: Metal burrs can form on the surface of workpieces. Belt grinders remove these burrs. Additionally, they are used for edge breaking and rounding metal materials.
• Surface Finishing: Like belt sanders, grinders are used for sanding, smoothing or roughing the surface of a material. This can also include removal of tiny burrs, polishing and cleaning the material, removing mill marks and edges.
• Removing Material: Belt grinders are commonly used to sand metals and remove material. For example, belt grinders are commonly used in knife making to shape metal blades. Typically, belt grinders are designed to remove tiny bits of material with each pass.

Considerations When Buying Belt Grinders

It’s important to match the belt grinder to the work that you will be doing. And to accomplish this, there are many considerations you will need to make. The two biggest include:

• Belt size: Belts for grinders average from about 1.5 to 6 inches in width. Wider belts are used for larger work pieces, while narrower belts allow for more precision. If you want to use a range of belt sizes, choose a grinder that can accommodate more than one width.
• Belt Speed: Typically, faster belt speeds are required for removing material more quickly. Slower speeds are best-suited for smoothing and deburring metals. Choose a belt grinder that has a selectable range of belt speeds.

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Types of Carbide Bits

Choosing a proper carbide bur is dependent on a number of factors. For example, the “shank size” of the bur must fit the rotary tool, and there are a number of sizes. Secondly, the shape of the bur and the fluting – or the bur cut – is determined by the workpiece material, as well as the desired cut.

• Shank Size: A bur’s shank is the stem that fits into the rotary tool, and it’s important to properly size the shank. For example, a bur with a 1.6mm shank is not compatible with a 3mm rotary tool. In general, the most common shank sizes are:
  • 6mm
  • 35mm
  • 3mm
  • 6mm
• Bur Size: Additionally, the size of the rotary file should be considered. The two most important measures are cut length and diameter. These are the dimensions of the cut the rotary file will make, and they range in size from a few millimeters up to 15mm or more. The size you’ll need depends on the size of the cut or chamfer that you’re trying to create.

• Bur Shape: Carbide rotary files are available in a variety of shapes. Each shape is designed for a specific application, and choosing the shape is also dependent on the cut that the user wants to achieve. The most common are: cylindrical, ball shaped, egg shaped, flame shaped, pointed nose tree, tapered, inverted taper, countersink, round nose tree and cylindrical ball nose. For example, ball shaped rotary files are generally used to hollow out material, while tapered burs are used to round off, or chamfer, edges.
• Fluting Style: The bur’s fluting refers to the grooves on the surface of the bit. There are two main types including single-cut and double-cut flutes, and both are used with different types of materials. For example single-cut carbide burs have a spiral flute in one direction, and they are typically used with ferrous metals, copper and steel. Double-cut burs, on the other hand, have a crisscross pattern created by spiral flutes in opposite directions. Double-cut burs provide a smoother finish, and they’re generally used with softer metals and hard woods. The fluting is also rated by coarseness of the burr, with fine, standard and coarse cut options available.

  

Carbide Rotary File Safety Tips

In general, rotary files are fairly safe to operate. As the grooves or fluting is so fine, they often will not cut the skin when lightly touched. Yet, there are a few things to keep in mind for safe operation and to extend the life of the bur. These include:

• Ensure the bur shank is tightly clamped within the collet, and that it is inserted as far as possible to diminish overhang.
• Use light pressure, as excessive downward force can cause snagging and lead to cut blemishes and chipping. Let the bur do the cutting.
• Secure your workpiece tightly and wear eye, and/or face protection.
• Don’t use an excessive spinning speed. Instead, start at a slower speed, and gradually increase speed.

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Choosing the right toggle clamp depends on the type of work that you will be doing. For instance, there are specially made toggle clamps to aid in welding and metalworking, which are heavier duty, and there also different types depending on your height requirements. For example, horizontal toggle clamps can fit into low height locations better than vertical toggle clamps. So what type of toggle clamp is right for you?

Common Toggle Clamp Devices

There are many different types of toggle clamps. Each one of the clamps is available in a variety of heights, which allow the clamp to hold onto different objects. Plus, they are all capable of different holding capacities and some toggle clamps are portable, while others need to be fastened to a work bench. These are all factors that should be considered when determining the type of toggle clamp you need.

The various types of toggle clamps include:

Vertical Hold-Down Toggle Clamps: The handle of a vertical toggle stands straight up when locked, and they are designed with various holding capacities. Generally, they’re capable of applying a considerable amount of pressure. By pulling the handle away from the object, the securing bar is lifted and an object can be placed under the bar. Then, pressure is applied as the handle moves into vertical alignment. These are secured to a worktable and are often used to secure wood or objects around machinery. For instance, these work well when securing an object that will be cut with a jigsaw.

Horizontal Hold-Down Toggle Clamps: Horizontal toggle clamps are similar to vertical clamps, but they are aligned differently. With these clamps, the handle and securing arm start semi-vertical, and as the handle moves toward the table, the securing arm locks into place. These are commonly used when there are height limitations due to machinery. Plus, they must be mounted to a table.

Push-Pull Toggle Clamps: The handle of a push-pull or straight-line toggle clamp moves the securing bar in a straight line, hence the name. When the handle is engaged, the securing arm pushes into the object and locks, effectively holding it in place. Generally, push-pull toggle clamps can be locked in two positions, and they are best suited for holding objects together, like molds or two pieces of wood.

Pull-Action Latching Toggle Clamps: These toggle clamps work similar to the latch on a fishing tackle box. With these types of toggle clamps, the handle is aligned with the opposing latch, and it is pulled back down into the locking position. These types of toggle clamps are commonly used for closing objects like mold closures or for latching doors.

Squeeze-Action Toggle Clamps: Squeeze-action clamps look similar to a set of plyers. They have two jaws that clamp onto objects when squeezed together. These are portable clamps that can be used in a variety of situations to hold two objects together or an object in place. For instance, if you needed to clamp two boards together, but you were away from your shop, you could accomplish that with squeeze-action toggle clamps.

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