Sanding performance and failure progress of precision-shaped abrasive belt during sanding MDF

Ordinary coated abrasive belts (OCAs) are characterized by poor height consistency, irregular abrasive grit arrangement, and uncontrollable grit shape. These shortcomings lead to varying material removal rates, unstable surface quality, and shorter lifespans. To enhance the sanding process of wooden materials, a new precision-shaped abrasive belt (PSA) tailored to the attributes and cutting dynamics of wood was studied. In this study, PSAs were prepared using pyramidal structured abrasive grits with desired shape and angles between side-front faces (side-face angle). A sanding test was conducted on medium-density fiberboard (MDF) using OCA, as a control reference, along with PSAs. The sanding performance and service life of the PSAs with five side-face angles were evaluated through the analysis of the MDF removal amount by abrasive belts, surface roughness of MDF samples sanded using abrasive belts, and mass loss and surface morphology of the abrasive belts. The result revealed that PSAs exhibited a higher sanding stability than OCA. Moreover, both removal efficiency and surface quality of MDF depended on the side-face angle of PSA. A reduction in the side-face angle of PSA decreased its contact area with the MDF sample, resulting in an increased cutting depth and higher MDF removal rate with poor surface quality of sanded MDF face. Additionally, the side-face angle played a vital role in dust removal, with a smaller side-face angle being less susceptible to blockage by wood dust. PSA can easily adapt to various machining requirements depending on its grit structure and arrangement. This study provides theoretical support and practical guidance for PSA research and production.