Grinding Stones
Grinding stones are used to shape, level, polish, and finish roll and cylinder surfaces. Selection should consider the roll material, diameter, existing surface condition, finishing stage, grit, machine speed, pressure, feed speed, and target roughness.
Shinano SD-Grinding Wheel
Shinano Electric Refining was founded in 1921 and is recognized as an early Japanese producer of silicon carbide. Its SD-Grinding Wheel combines selected silicon-carbide grit with a polyvinyl-formal sponge structure for precision finishing of copper-plated gravure rolls.
The wheel provides controlled elasticity, low surface roughness, reduced scratching and irregularity, resistance to clogging by copper particles, longer service life, and improved grinding efficiency.
The brochure states that a #2000 wheel can polish approximately 20–30 copper rolls with a surface area of 0.5 m² under referenced conditions. A surface roughness of approximately Ra 0.07 μm can be achieved with a #3000 wheel under the stated test conditions.
Grade | Mean grit diameter | Recommended stage |
|---|---|---|
SD-500 | 25.0 μm | Rough finishing |
SD-800 | 14.0 μm | Rough finishing |
SD-1000 | 11.5 μm | Rough finishing |
SD-1500 | 8.0 μm | Medium finishing |
SD-2000 | 6.7 μm | Fine finishing |
SD-2500 | 5.5 μm | Fine finishing |
SD-3000 | 4.0 μm | Mirror finishing |
Standard wheel dimensions are approximately 200 mm outside diameter, 50 mm inside diameter, and 50 mm thickness. Other dimensions may be available on request.
Typical grinding references include wheel speeds of 300–900 rpm, cylinder speeds of 200–300 rpm for hard copper or 90–120 rpm for soft copper, traverse speeds of approximately 200–300 mm/min, and total grinding pressure of approximately 10–25 kg. Actual settings must be determined through testing for each machine, roll, and surface condition.
Typical process sequences include:
- Used-cylinder recovery: #800 → #1500 → #3000 → buffing
- Rough cylinder: #1000 → #2000 → buffing
- Ballard shell: #800 or #1000 → #2000 or #3000 → buffing
Shin-EI High-Speed Roll Grinding Wheels
Shin-EI has developed resinoid-bond grinding stones since 1941. Its materials emphasize that roll quality begins with correct rough polishing and that the stone must be selected according to roll material, roll size, polishing pressure, stone speed, roll speed, and feed speed.
Using a copper-roll stone on steel can cause steel particles to load the stone surface and scratch the roll. Using a steel-roll stone on copper can cause the stone to wear too quickly and increase replacement cost.
| Roll material | 30–40 kg polishing pressure | 50–70 kg polishing pressure |
|---|---|---|
| Copper | A180-T to A220-T | A320-R to A500-CS |
| Steel | A180-P to A220-P | A320-P to A500-CO |
For rolls with a circumference above approximately 600 mm, a softer resinoid or PVA stone may be more suitable. The brochure also references machine-head mounting dimensions of approximately 200 mm diameter × 50 mm thickness × 50 mm hole diameter.
An example rough-polishing condition using A220-S includes 500–600 rpm stone speed, 30–40 kg pressure, 60–80 rpm roll speed, and 600–800 mm/min feed speed. These are application references, not universal operating settings.
The process range covers rough polishing with resinoid stones, medium polishing, copper-plating preparation, fine finishing with PVA stones, buffing, and chrome polishing
Pioneer Gravure Grinding Stones
Pioneer Fine Grinding Materials manufactures synthetic grinding stones and related gravure-cylinder equipment. Its product range includes stones for steel, copper, chrome, stainless steel, and multifunctional applications.
Available grit references range from #100 to #6000, covering rough grinding, intermediate finishing, fine finishing, and high-precision surface work. Standard size references include approximately 200 × 50 × 50/75 mm and 200 × 100 × 50/75 mm.
Key characteristics include:
- Low stone wear and long service life
- Strong cutting force and high efficiency
- Mechanical strength suitable for different applications
- Different inside and outside diameters
- Reduced risk of scratching gravure cylinders
- Quality control intended to reduce unreasonable diamond-tool wear and cylinder rework
Stone hardness should match pressure, rotation speed, passage speed, and cylinder circumference. Higher pressures and higher rotation speeds require harder, more compact stones. Lower pressures and lower speeds require softer stones to promote abrasive exchange and maintain cutting performance.
Pioneer also offers special-shaped grinding stones designed to reduce conventional grinding patterns, improve surface smoothness, and support demanding gravure and gradient-printing requirements.
Additional Pioneer Consumables
The Pioneer portfolio also includes cotton filters, carbon filters, seal circles, electroplating additives, polishing paste, fabric wheels, polishing tape, and related cylinder-making consumables.
Pioneer Cylinder-Making Equipment
The broader Pioneer range includes gravure-cylinder grinding machines, copper-polishing machines, chrome-polishing machines, printing proof presses, and automatic plating lines.
AION Grinding and Polishing Materials
AION grinding materials use PVA sponge as a bonding medium. The continuous open-pore structure combines flexibility, elasticity, high porosity, and heat dissipation, allowing the abrasive grains to adapt to the workpiece surface.
This “soft-to-soft” finishing behavior helps reduce deep scratches and surface damage. The open pores limit heat generation and clogging, supporting stable grinding even with soft metals and materials that normally generate heat easily.
Key characteristics include:
- Elastic contact that adapts to the workpiece
- Continuous open pores that dissipate heat and debris
- Low risk of clogging
- High-precision finishing with minimal visible scratches
- Grain and bonding options for different materials and finishing requirements
- Potential reduction of conventional lapping or buffing process time
AION for Soft-Metal Lapping
AION A/LP- and M/LP-type stones are used for aluminium substrates and other relatively soft metals such as copper, brass, and selected stainless steel components. Grain sizes are available for rough grinding through high-precision finishing.
AION for Roll Grinding
AION products are available for plastic rolls, copper rolls used in gravure printing, aluminium rolls, and other roll materials. Their elastic structure supports sharp surfaces, fine finishing, and economical operation.
AION for Paint, Glass, and Precision Components
The broader AION portfolio includes products for paint-surface retouching, glass chamfering and edge work, magnetic heads, deburring, and precision finishing of selected metal and electronic components.