What is Industrial Abrasive - Types, Uses and Materials

The glossy shine of a stainless steel sink and the precision-machined finish of airplane components share a common manufacturing secret: abrasives. Behind virtually every smooth surface and precisely shaped component lies the work of specialized abrasive products that transform raw materials into finished goods. 

So, what is an industrial abrasive? Industrial abrasives are hard substances used to grind, cut, or polish softer materials, serving as the foundation for countless manufacturing processes across industries.

Below, we’ll explore the different industrial abrasives and materials, from the basics to the specific abrasive tools and applications that depend on them.

What is an Industrial Abrasive?

To expand on what we mentioned above, an industrial abrasive is a hard substance used to shape an object through friction and rubbing. These substances may be natural abrasives or synthetic abrasives. They scrape away material from the targeted surface by using tiny, sharp edges. To determine an abrasive's effectiveness, you must consider the hardness and grit size of its particles, the quality of its binder, and the base material used for the tool.

The primary functions of an abrasive are cutting, removing material, and creating a specific surface finish. For fast material removal, use coarse grits. For delicate polishing and a smooth finish, use finer grits.

Types of Abrasives

Abrasives are classified based on their origin and hardness, which directly affects their applications.

Natural Abrasives

Natural abrasives are derived from minerals found in nature and were historically the only option available before synthetic alternatives were developed. 

Common examples include garnet, quartz, emery, and natural diamond, which ranks as the hardest substance on the Mohs scale. Glass beads and steel shot are also considered natural abrasives, particularly for blasting applications. These materials are typically used on softer substances such as tin and non-ferrous metals like aluminum.

Synthetic Abrasives

Modern industry relies heavily on synthetic abrasives due to their consistent performance, superior purity, and reliable quality control. These artificially manufactured abrasive grains are produced under strict manufacturing guidelines to ensure uniformity and predictable results. 

Common examples include silicon carbide, valued for its exceptionally sharp and hard particles, and aluminum oxide, a durable material widely used for working with wood and most metals. The most advanced synthetic abrasives include synthetic diamond and cubic boron nitride, which fall into the specialized category of superabrasives.

Superabrasives

Superabrasives are a class of materials with exceptionally high hardness, making them ideal for working with hard metals and ferrous alloys, such as steel and iron. The most common superabrasives used today are synthetic diamond and cubic boron nitride. These materials are specially designed for precision work and applications where conventional abrasives would wear out too quickly.

Common Abrasive Forms and Tools

Abrasives are integrated into various cutting tools, each designed for a specific machining process.

Coated Abrasives

Coated abrasives consist of abrasive particles attached to a flexible base material such as paper, cloth, or vulcanized fibers. These are some of the most widely used abrasive products in the industry today.

Common examples include sanding belts, abrasive belts, fiber discs, and flap discs. Flap wheels are another type of coated abrasive that is particularly valued for their adaptability to curved and contoured surfaces. The exposed sharp edges of the particles allow for effective sanding and material removal.

Bonded Abrasives

In bonded abrasives, the particles are combined with a binding agent and shaped into a specific shape, such as a wheel or grinding stone. A common example of this is the cut-off wheel used on an angle grinder or abrasive chop saw. Grinding wheels used on bench grinders are another form of bonded abrasive, designed to withstand high pressure and high temperatures without losing their shape.

Abrasive Blasting and Specialty Tools

Abrasive blasting uses a high-pressure air stream to deliver an abrasive medium to clean, scrape, or carve a surface. Specialized tools such as abrasive discs, cutting tools, and drill bits are designed for specific power tools or machines.

For precise, intricate cuts, modern cutting tools like the waterjet combine a high-pressure water stream with an abrasive material.

Different Applications of Industrial Abrasives

Industrial abrasives are used in a wide range of industries for tasks that involve shaping, finishing, and polishing materials. Each industry utilizes different abrasive tools tailored to its specific requirements:

Related Article: How to Cut Metal For Every Project Using Tools and Materials

Choosing the Right Abrasive

Selecting the right abrasive is crucial to success in various industrial applications. The best choice depends on several factors: the hardness of your workpiece, the machining process required, and the desired surface preparation or smooth finish. For example, when working on stainless steel, choose a hard abrasive that will not corrode the metal, while for glass, a fine-grit silicon carbide abrasive may be the best choice.

Performance factors include cutting efficiency, high-speed rating, and heat resistance. A good abrasive has a uniform cutting edge and high hardness, ensuring it lasts a long time and delivers the desired results. Selecting the right product from a variety of options is the key to achieving a professional finish.

The Foundation of Precision Manufacturing

Industrial abrasives serve as the backbone of modern manufacturing, enabling the transformation of raw materials into precisely finished products across countless industries. From general-purpose industrial supplies to highly specialized precision tools, the selection of appropriate abrasive technology directly impacts project outcomes, production efficiency, and final product quality.

Understanding the relationship between material properties, abrasive characteristics, and application requirements is essential for optimizing manufacturing processes and achieving superior results. Benchmark Abrasives provides comprehensive abrasive solutions engineered to meet the demanding specifications of today's advanced manufacturing environments.