Grinding operations are central to the UAE industry, where metals, rails and concrete structures are processed. Productivity and safety depend not only on the choice of grain or bundle, but also on two key factors, the speed of operation and the applied pressure. These parameters directly determine the cutting efficiency, surface quality, and service life of the grinder wheel itself.
Rotation speed and movement of the tool
In conditions of active and passive grinding, the speed determines the nature of the interaction of the wheel with the material. In the active method, the motor makes the tool rotate at a speed of 3 to 20 km/h. This approach provides deep metal removal, but is accompanied by high wear. Passive grinding, on the contrary, involves using the speed of the train or equipment itself — up to 60-80 km/h. In this case, the wheel does not receive a drive, but rotates due to pressure and friction. This method has proven to be more gentle for the wheel itself and effective in terms of preventive maintenance.
Pressure and its effect on wear
Pressure plays a dual role. It speeds up the material removal process, but at the same time increases the load on the grain and the bundle. The optimal practical values for industrial applications range from 2000 to 2400 N. Below 2000 N, the grinder works gently, but does not remove defects in time. Above 2400 N, cracks appear on the surface, the abrasive is discolored, and the service life is drastically reduced.
It is important to understand that with increasing pressure, not only the yield increases, but also the friction force. The price of such performance is accelerated wear and reduced durability. For operation in the hot climate of the Emirates, this factor requires special control: overheated wheels lose their shape faster and can collapse.
Thermal regime and work safety
The temperature in the contact area determines both the surface quality and the life of the tool. The longer the removal time and the higher the load, the more intense the heating. In the passive multipass mode, the temperature increases more evenly, and heat surges are compensated by the presence of fillers, such as pyrite (FeS2).
Pyrite performs an important function, it absorbs heat and forms Fe2O3 and SO2 during the reaction, reducing the likelihood of overheating. In short cycles, it is consumed gradually, which slows down the wear of the ligament and stabilizes the process. In long cycles, on the contrary, Surface quality and service life pyrite burns out faster, and the ligament loses strength, which leads to the appearance of pores and accelerated wear of the grinder wheel.
Surface quality and service life
The roughness of the treated surface remains one of the most important indicators. Repeated short grinding improves the quality of the profile and reduces defects. In addition, the cutting force remains more stable for short bursts. For the operator, this means less risk of damage to the workpiece and less fatigue. Experts within the tools suppliers in UAE space can help select the right tool.
All in all, speed and pressure are two crucial parameters that shape the durability and efficiency of grinder wheels. For the UAE industry, where the volume of work is large and the climate increases the load on the equipment, the optimal solution is to use passive multi-pass grinding at a controlled pressure of 2000-2400 N. This mode provides a better surface, prolongs the life of the wheel, keeps the temperature within safe limits and reduces downtime.
