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Buffing and polishing using wheels and compounds is somewhat like using wet
and dry sandpaper, only much faster. Instead of using elbow grease, you use
the power and speed of an electric motor. The face of the wheel is the "sanding
block," which carries a thin layer of compound (sandpaper) to the part.
Color buffing further refines the surface and brings out maximum luster. The
workpiece should be moved toward the direction of the wheel using medium to
light pressure.
Buffs are created from cotton (muslin), canvas, chamois, sisal or string. They
may be loose, sewn, ventilated or pocketed. The following list provides
descriptions of several types of buffs:
Loose buffs have several plies of material with a row of sewing around the
center hole. These buffs are most often used for the final buffing operation
prior to plating. Because the wheel is not tightly stitched, it will collapse,
allowing cotton to get into awkward places more easily. The best loose buffs
are 100% cotton.
Bias-type buffs are probably used most often in the industry. The cloth is cut
at a 45-degree angle, wrapped about a drum and squeezed into a clinch ring.
These buffs combine flexibility and cutting power. A weaving pattern (spacing)
between the sections provides for natural ventilation. Bias buffs can be
customized to work with various sized parts and to provide degrees of cut and
color.
Folded (pocketed) buffs have disks of material folded to form pockets that hold
compound. These buffs are mounted in one direction for cutting and mounted
the other way for coloring. They provide fast cutting and good flexibility.
Sisal buffs are made from a strong cloth and may be plain or treated, full disk
or ventilated with a center metal clinch ring. These aggressive buffs provide
polishing and cutting action and are most often used on ferrous metals.
However, they can be used on nonferrous metals as well. Sisal buffs soften and
become flexible from the heat generated during the buffing operation.
String buffs are soft and flexible for use on plastics or precious metals to avoid
leaving buff marks. These buffs are also good for coloring precious metals
since they leave no buff marks.
Buffs can have up to 100 layers of cloth or plies. They can have soft, medium or
hard densities, which refers to the thread count of the cloth. A higher thread
count indicates a stronger, harder cloth with greater cutting ability.
Buffing wheels have a variety of designs, and run at speeds of 5,000 to 8,000
sfm. Each wheel should run for a few seconds prior to use. Also, buffing wheels
have safe and unsafe areas. The safe area rotates away from the work piece and
toward the operator. The unsafe area rotates toward the work piece. The work
piece must be applied only to the area of the buff that is rotating away from the
work piece. Objects thrown away from a buffing wheel travel at high speeds,
which could result in serious or potentially fatal accidents.
Tripoli buffing compound has been around a long time and is one of the most
popular compounds for cutting down and producing a high luster on
nonferrous metals. There are several types of Tripoli compounds, depending
on the type of finish desired and on the substrate.
Chrome rouges are used for buffing chromium and stainless steel. The cut
varies from mild to fine and sharp. Rouges are made of mild oils and greases
with alumina abrasive.
There is also jeweler's rouge. Red rouge brings out a high color on gold, silver,
sterling, platinum and brass. White rouge produces a brilliant finish on
chromium, stainless steel, steel, brass and aluminum. Green rouge is used for
fine color buffing on all types of metal.
Steel compounds vary in color from nearly black to light gray depending on
the composition. These compounds are used to buff iron, steel, stainless steel
and some aluminum and brass castings. Steel compounds vary in cut
depending on the kind of sisal buff used and the amount of grease in the
compound. Stainless steels can be easy to buff or nearly impossible depending
on the condition and type of steel. When buffing stainless, use a dry- or
medium-dry compound on untreated full sisal or laminated sisal buffs.
White coloring compounds are used for buffing nonferrous metals that are in
good condition to produce a mirror-bright finish. It can also be used on
copper-plated articles when a regular Tripoli compound would be too severe.
The same abrasive powders are used in spray compositions; however, the
binders are different. Binders are used in oil solutions or water emulsions so
that they are fluid at room temperature.
Polishing
Polishing is not a precision operation. It is used to remove metal and produce
fine-scale abrasion. Friction generates high temperatures that can soften the
surface of the workpiece. Polishing, which usually involves several stages,
precedes buffing.
Polishing stages begin with a rough polishing stage using abrasive grit sizes of
36 to 80. Second stage uses abrasives sized from 80 to 120. For the first two
steps the wheels are used dry. The third stage uses 150 size and finer grit. In
this stage, the wheels are slightly worn down and coated with oil, beeswax or a
similar substance. This step is actually part polishing, part buffing, since more
abrasive is usually added with the grease.
Pressed felt wheels have densities that are extremely hard as well as extra soft.
These wheels are used when uniform density is required over the entire
surface of the wheel. The felt face contours easily to fit irregularly shaped
parts.
Wire wheels can be constructed from stainless steel, brass or nickel wire.
These wheels remove rust, scale, burrs and coatings, as well as providing a
satin finish or highlighting oxidized finishes on brass, copper or silver.
Most polishing operation speeds range from 5,000 to 7,500 sfm. High-
strength steels and stainless steels are polished at the higher rates; however,
excessively high speeds may burn workpieces. Wheels that are more rigid are
used for coarser polishing where rapid metal removal is needed. Rigid wheels
are also used when the surface is regular and not contoured or irregularly
shaped. Wheels that are more flexible are better for polishing and use on
irregular surfaces.
Buffing and polishing may seem like simple operations. You simply hold the
work piece to the wheel until it shines. But there is an art to it, and you need to
know the basics before you can make rough surfaces smooth and dull surfaces
shine.
References
Maroney, Marion L., A Guide to Metal and Plastic Finishing, First Edition,
Industrial Press Inc., 1991, New York, New York.