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Surface finishing with abrasive brushes is a wide and extensive branch of the general surface finishing. H. Günther Falkenrich GmbH offers the broadest product range in its industry. With some 3,500 variants, regardless of the dimensions, we offer for almost every application the perfect tool. In addition to the theoretical advice from our team of experts in the sales meeting, we offer free practical processing of your samples in our house. Our company's own laboratory provides grinding test with his hands-on equipment. We are capable of applying all possible methods for the perfect use of the products prior to integration into your existing processes. This accelerates the product determination and does not interrupt your own production. Should our machines not be sufficient for your requirements, additional testing will be conducted in the industry. We are also cooperating with machine manufacturers and users.

Test Laboratory - Demonstration and Testing

• arrow_drop_downGeneral Technical Information about non-woven Materials

  Working Speed

  When selecting the working speed for non-woven material products it is most important to consider two different criteria:

  1. The maximum speed provides a sufficient degree of safety, and stays within the physical limitations of the relevant tool construction.
  2. The functional speed corresponds with the working speed in order to achieve the required results.

  The following recommended peripheral speeds have been established in numerous tests. These tests have clearly indicated that the functional speed for our products is lower than the stated maximum speed. Subsequently, the stated maximum operating speed should not be exceeded, not even for test purposes. The best setting for an optimum functional speed can often only be determined after briefly testing the chosen tool on the relevant work piece, particularly if it is important to improve the visual appearance of the work piece.

  Advice

  1. The lower the working speed, the longer the life span of the tool.
  2. The higher the working speed, the greater the grinding effect, the shorter the life span of the tool.

  Falkenrich-Product	Material	Recommended working speed / peripheral speed
  Non-woven flap wheel (not impregnated)	Wood Steel Stainless steel Non-ferrous metals	10 - 12 m/s 12 - 20 m/s 10 - 15 m/s   7 - 15 m/s
  Non-woven flap wheel Non-woven convoluted wheel	Steel Non-ferrous metals Plastic	17 - 24 m/s 10 - 28 m/s 12 - 18 m/s

  Conveyor Speed

  The feed rate determines the speed at which the work piece is conveyed past the tool. It is expressed in meters per minute (m/min). The 'process time' is dependant on the feed rate. The process time is the time during which the work piece is in contact with the tool.
  The longer the process time, the greater the grinding effect.

  Direction of Feed

  The work piece can be conveyed in the direction of rotation or vice versa. If the tool moves in the opposite direction to the work piece, the relative process time is longer and therefore the grinding effect on the material is greater. Therefore, if the line pattern is shorter a greater cutting depth is effected. If the tool moves with the direction of the work piece, the process time is shorter, hence a regular finish is created with a longer line pattern.

  Applied Pressure

  The grinding effect can be influenced by applying different pressures:

  • Longer process time
  • Better cutting performance
  • Faster machining

  Advice

  1. Higher pressure provides higher grinding effect.
  2. Lower pressure provides lower grinding effect.
  3. oo much pressure can cause smearing of the non-woven material products.

  Cutting speed as a function of rotational speed (rpm) and diameter:
  General formula: [AD-Ø (mm) x 3,1416 x U/min] / 60.000 = m/s

• arrow_drop_downTechnical Information about the mechanical Treatment of Circuit Boards with non-woven Roller Brushes

  Nature of fault	Cause of fault - machine	Cause of fault - roller brush	Remedy of fault
  The markings are running diagonally to the running direction	Damaged bearings Jamming of the work piece feed	Unbalanced rollers through incorrect operation	Maintenance of the brushing machine Take off the brush and/or send it off for strip threading
  The panels are only brushed on one side in the direction of the feed	The roller brush is not aligned parallel to the counter pressure roller	The roller brushes are possibly not round or conical	Take off the brush and/or send it off for strip threading
  Longitudinal lines on the PCB's	Faulty rinsing unit The conveyor and/or counter pressure rolls are dirty	The roller brushes are blocked with residues Damaged roller surface	Repair the rinsing unit, if necessary get it serviced and properly adjusted Clean the machine Send off the rollers for strip threading or remove them Adjust the oscillation
  The boards are only brushed in parts	Incorrect contact pressure	The brushes are too hard	Adjust the contact pressure Select appropriate brushes
  The burr was not removed	Incorrect contact pressure Incorrect feed Incorrect rotation direction of the brushes	The brushes are too soft Incorrect abrasion	Select appropriate brushes Adjust the abrasion Adjust the rotation direction Adjust the feed Adjust the contact pressure
  The burr partially comes to a halt	Rinsing unit is not correctly adjusted	The brush is blocked	Take off the brush or send it off for strip threading
  The burr is pressed into the bore / secondary burring	The rinsing unit is not correctly adjusted Incorrect contact pressure Feed too fast	Blocked brush The brush is too soft	Repair the rinsing unit and adjust properly Adjust the contact pressure Adjust the feed Take off the brush and/or send it off for strip threading Select the appropriate brush
  The drill hole edge is very rounded	Incorrect contact pressure Feed too slow	The brush is too soft Incorrect abrasion	Adjust the contact pressure Adjust the feed Select the appropriate brush
  The drill hole is ovalised	See above	See above	See above
  Problems with the adhesion undercut	The rinsing unit is incorrectly adjusted or damaged	Incorrect abrasion	Select the correct abrasion
  Blocked bores	The rinsing unit is incorrectly adjusted or damaged Defect filtration Poor water quality	High brush grinding effect Loosened particles are too big Irregular grinding effect	Repair the rinsing unit and the filtration and adjust properly Use filtered water Select the appropriate brush à Falke long life-DEBU-impregnation Have the step turned
  Thin inside layer Bending of edges	Incorrect contact pressure Incorrect rotation direction of the rollers	The brush is too hard	Select the appropriate brush Adjust the rotation direction Adjust the contact pressure
  Damaged multi layers Only partial brushing of the surface	Incorrect pressure Incorrect feed	The brush is too hard	Select the appropriate brush Adjust the contact pressure Adjust the feed
  The press panels are not properly cleaned	The rinsing unit is incorrectly adjusted or damaged	The brush is blocked or full of glass	Select the appropriate brush Take off the brush and/or send it off for strip threading

  
  

  Brushes with recessed edges have the following advantages:

  • No damaging of the billy rolls
  • 100 % transferring of brush pressure on the PCBs
  • Avoiding of residues from the board
  • Indicated by a "T + mm" in the product designation, e.g. 23 MS 07 T 15

  
  

  

  
  

  We recommend following adjustment of your water supply in your brushing machine:

  
  

  

• arrow_drop_downSafety Instructions

  

  Please wear suitable hearing protection!

  

  Please wear suitable eye protection glasses!

  

  Please wear suitable gloves!

  

  Please wear a suitable dust mask!

  When using our products by machine, please follow the technical instructions and instructions of the machine manufacturer!

• arrow_drop_downDownload

  • Certificate DIN EN ISO 9001:2015, englishpicture_as_pdf
  • Falkenrich brochure, englishpicture_as_pdf
  • Material Safety Data Sheet, englishpicture_as_pdf
  • FEPA Safety Recommendations for the use of abrasive products, englishpicture_as_pdf
  • Sales and delivery conditions, germanpicture_as_pdf
  • Declaration of Conformity - Conflict Minerals Regulationspicture_as_pdf
  • Declaration of Conformity - POPpicture_as_pdf
  • Declaration of Conformity - TSCApicture_as_pdf

• arrow_drop_downPress Panel Cleaning

  Assembly instructions for roller brushes for press panel cleaning

  1. Place the roller brush on the 'Wesero' assembly carriage and fold down the brush shaft supports.
  2. Guide the brush shaft into the bore (inner diameter = 190mm) of the roller brush. Take care not to damage the balancing threads situated inside the roller.
  3. Push all the required adapters onto the brush shaft, taking care to ensure they are not pushed into the bore of the roller brush.
  4. Lift the roller brush on one side and fold up the shaft support. Secure the support with the screw provided.
  5. The roller brush and the brush shaft are now positioned concentrically to each other. Now, one by one, push all the adapters into the bore of the roller brush. Do not use hammers or excessive force to position the adapters!

  Some more advice

  The balancing weights are adhered in the laminated paper tube. Take care that these weights are not damaged or removed on installation of the shaft. Insert the aluminium flange with a separating agent (e.g. Lithium soap fat). Ensure that the driving pin is positioned correctly. Any jamming of the flange can cause the roller to break. We recommend 17m per second as an ideal operating speed for new rollers; if the rollers are almost worn we recommend a speed of approx. 14 m per second. The rotation direction of the roller is marked by an arrow on the side. The water pressure for your brushing machine should be in the region of 3 bar.

  Adjusting the roller brushes of the 'WESERO' for wet operation

  1. Switch off the machine and open the lid.
  2. Switch the machine to manual operation and turn the roller brushes down (release the contact pressure) to a point where they can be turned by hand.
  3. Prior to levelling, the brushes must be thoroughly spinned without water being added by turning them for about 15 to 20 minutes.
  4. Check the roller surface and the roller heads for any exterior damage. If the roller heads are protruding they should be levelled with a right angle grinder prior to use. Note: the roller body must only be turned by hand.
  5. Separate the brushes further after the heads have been levelled and switch on the brushes that still need to be levelled with oscillation.
  6. Insert the adjusting plate into the machine to a point where the plate of the conveyor roller will be gripped in front and behind the brushes, which are to be adjusted.
  7. Now switch on the brush and adjust to a point where the operating level indicates 30% - 35%. Then the feed must be switched on and off in short intervals of approx. 5 seconds. (Caution! - Longer process times will destroy the brush and the adjusting plate!). Ensure that the capacity intake is always between 30% -35%, if necessary, adjust via the in-feed. This procedure must be repeated three to four times.
  8. The same procedure applies to the following brushes. Ensure that only the brush that is to be treated is switched on during the complete levelling process.
  9. When the levelling process has been completed, the adjusting plate must be retracted, to avoid any soiling of the conveyor rollers inside the dryer. Clean the engine compartment with water afterwards.
  10. Ensure that the jets are clean and the jet beam pints in the direction as specified in the manual, before the machine is operated again.

  Adjusting the roller brushes of the ' WESERO' brushing machine for dry operation

  1. Switch off the machine, open the lid and take out the suction trough.
  2. Switch the machine to manual operation and turn down the roller brushes (release the contact pressure) until they can be turned by hand.
  3. Check the roller surface and the roller heads for exterior damage. If the roller heads are protruding they should be levelled with a right angle grinder prior to use. Note! The roller body must only be turned by hand.
  4. Install the suction trough and switch on the duster.
  5. Separate the brushes further after the heads have been levelled and switch on the brushes, that still need to be levelled with oscillation.
  6. Insert the adjusting plate into the machine to a point where the plate of the conveyor roller will be gripped in front and behind the brushes, which are to be adjusted.
  7. Now switch on the brush and adjust to a point where the operating level indicates 30% - 35%. Then the feed must be switched on and off in short intervals of approx. 5 seconds. (Caution! -Longer process times will destroy the brush and the adjusting plate!). Ensure that the capacity intake is always between 30% -35%, if necessary, adjust via the in-feed This procedure must be repeated three to four times.
  8. The same procedure applies to the following brushes. Ensure that only the brush that is to be treated is switches on and the suction device is switches on during the complete levelling process.
  9. When the levelling process has been completed, ensure you clean the machine thoroughly and hoover the brush surface.