WHY DO MY SANDING BELTS KEEP BREAKING?

 1.Understanding Sanding Belts

Sanding belts are commonly used multi-purpose tools that are generally used for scribing, flattering and wood finishing. They are used to level out rough surfaces, resulting in a smooth surface. The diligence related to metalwork and woodwork has been smartly replaced by sanding belts for good. As a result, the users of sanding belts can perform sanding and grinding easily and in a short period.

There are several types of sanding belts and it is important to choose the right sanding belt that is suitable for the relevant task. Using the wrong sanding belt might result in the damaging of the materials as well as the belt sander. Sanding belts are made of different materials like ceramic, zirconia, aluminium oxide and silicon carbide.

The uses of sanding belts run across various applications. They are used in woodworking, metalworking and auto body repair. In woodworking, sanding belts are used for shaping and refining wooden surfaces. Moreover, they are also used for removing paint or varnish and levelling rough surfaces and edges. Applying coatings or sealants on wood should be done only on smooth surfaces and sanding belts facilitate to ensure this smooth surface is present for coating.

They are also used for surface preparation, deburring and removing rust or paint from metal surfaces. Furthermore, sanding belts help in shaping metal pieces and smoothing out welded joints. Sanding belts are also used in auto body repair, where they can be used to remove paint or primer and other surface imperfections from car panels. They are also used in restoration projects.

2.Common Reasons Why Sanding Belts Break

While there may be various reasons for sanding belt breakages, it is important to identify and take proper measures for better usage. Given below are some such common causes resulting in sanding belt breakdown.

1. Compromised quality of belts - incorrect manufacturing processes of sanding belts may result in their breakdown. The manufacturer may have caused any errors in using the correct heat setting, or that the belt was scuffed improperly before it was taped and glued.

2. Too much pressure when using- Too much or too little of tension pressure on the belt while running can cause the belt to snap. It can also cause issues like belt folding, tracking problems and joint failure.

3. Improper working direction- Most of the sanding belts that are manufactured today are bidirectional, which means they can work in both directions. However, some of them are unidirectional. As a result, not running the belt in the recommended direction can cause breakages in the belts.

4. Improper Storage - Under proper care, sandingbelts can last for more than a year. However, they should be stored in a place away from moisture, condensation, excessive heat or cold. Failing to store the belts in a climate-controlled environment can result in the deterioration of joints in the sanding belt.

5. Overuse and Wear - Sanding belts may wear out based on the amount of usage. If sanding is regularly done, then overusing the sanding belt beyond its lifespan can occur. As a result, the sanding belt may experience breakage. This can be overcome by regular checking and replacing the belts within eight months to a year.

6. Unsuitable belt for application- The type of sanding belt used differs according to the different types of applications that particular sanding belt is used for. If the sanding belt breaks during use, a possible cause could be that the wrong sanding belt is being used for the particular process. For instance, paper-backed sanding belts are the most commonly used type of sanding belts, as they give a smooth finish and are relatively inexpensive. However, during heavy-duty use like sanding metal surfaces, paper-backed sanding belts may break due to their fragile nature. For these instances, a cloth belt can be used as a suitable replacement.

3.Troubleshooting and Solutions

Trying to identify the root cause of a broken sanding belt can be extremely difficult. The problem may be visible to your eye, or it can be inside the machine which comes out in the form of issues in the belt. Whatever the problem may be, here is a list of common visual defects that can be used to identify a damaged belt and their causes.

1. Chatter marks

• Incorrect roller
• Incorrect joining of belt
• Incorrect tension pressure
• Worn conveyor belt

2. Ridges

• If short, close ridges in a step formation occur, standing pressure might be too high.
• Medium-length ridges in a random formation can mean that there is an irregular belt speed, which may be too high or too low.
• Wavy lines might mean that there are impurities in the piece on which the sanding belt is being used.

3. Scratches

• Contamination in the belt joint
• Cracks in the abrasive coating

4.Step-by-Step Troubleshooting Guide

This section of the article lists some troubleshooting steps to overcome some common issues with sanding belts.

1. Breaking of sanding belts - If your sanding belts are new and start to break prematurely, you should probably check for the following.

• Improper belt backing
• Improper belt backing
• Improper joint
• Excessive load on the belt

2. Overloading or burning of belts- If your belts require constant replacements or leave marks on your workpieces, the following may be the reasons.

• Build up of resin or glue
• No changes in the entry point of the sander
• No variation in grit based on the application
• Belt requires replacing

3. Excessive dust- Accumulation of ust can result in burns on workpieces. Furthermore, it can also result in premature wearing of the sanding belt. This issue can be caused due to the following.

• High static electricity
• Malfunctioning of dust extraction system

However, if any of these steps do not turn in fruitful results, it means it could be time to seek some professional help to identify the problem and arrive at a solution.