Abstract: An elongated narrow and rather thin honing tool is made from a somewhat soft metal or plastic cup holder. A tightly packed bundle of abrasive containing plastic monofilaments is inserted to the bottom of the cup holder and the cup rim is swaged inwardly to girdle and grip the bundle holding the bundle in the cup holder. The projecting tightly packed tips of the monofilaments form the working face of the honing tool. The preferred plastic for the monofilaments is nylon and the preferred transverse sectional shape of such monofilaments is rectangular, although other plastics and shapes may be used. Several methods for forming the tool are disclosed which include an insertion step followed by a swaging step. The bottom of the cup may be slightly arcuate to impart a curved working face to the bundle. The bundle may be cut or trimmed before or after insertion.

Abstract: A process for forming a twisted stem tool uses a specially designed clamping jaw fixture at the nose or bight portion of a half-round wire or cotter pin which helps to reduce the required clamping force and distribute that force over the entire wire-fill material interface. The jaws of the clamping fixture engage the outside of the nose over a substantial area, and in some forms actually bite into the wire or pin. After the twisting operation, the stem is placed in a swaging or coining press, and the stem beyond the fill material is reformed into a three or six-sided drive stem. The cold flow of the metal to form the flat sides locks the twisted half round wire or pin sections together so that the stem will resist unwinding if the tool is driven in a reverse direction. The coining of the stem providing flats provides a tighter confinement of the bundle of fill material at the stem, and enables a common three or six jaw Jacob's style chuck, for example, to obtain a more secure grip.

Abstract: A process for forming a twisted stem tool uses a specially designed clamping jaw fixture at the nose or bight portion of a half-round wire or cotter pin which helps to reduce the required clamping force and distribute that force over the entire wire-fill material interface. The jaws of the clamping fixture engage the outside of the nose over a substantial area, and in some forms actually bite into the wire or pin. After the twisting operation, the stem is placed in a swaging or coining press, and the stem beyond the fill material is reformed into a three or six-sided drive stem. The cold flow of the metal to form the flat sides locks the twisted half round wire or pin sections together so that the stem will resist unwinding if the tool is driven in a reverse direction. The coining of the stem providing flats provides a tighter confinement of the bundle of fill material at the stem, and enables a common three or six jaw Jacob's style chuck, for example, to obtain a more secure grip.

Abstract: An elongated narrow and rather thin honing tool is made from a somewhat soft metal or plastic cup holder. A tightly packed bundle of abrasive containing plastic monofilaments is inserted to the bottom of the cup holder and the cup rim is swaged inwardly to girdle and grip the bundle holding the bundle in the cup holder. The projecting tightly packed tips of the monofilaments form the working face of the honing tool. The preferred plastic for the monofilaments is nylon and the preferred transverse sectional shape of such monofilaments is rectangular, although other plastics and shapes may be used. Several methods for forming the tool are disclosed which include an insertion step followed by a swaging step. The bottom of the cup may be slightly arcuate to impart a curved working face to the bundle. The bundle may be cut or trimmed before or after insertion.

Abstract: A plastic strap or tape having granular abrasive embedded homogeneously throughout is cut, shaped and formed into a variety of abrasive finishing tools. The plastic working element is preferably rather stiff 6/12 nylon and contains about 30 to 45% by weight of abrasive material. The strap or tape is formed by extrusion of such non-elastomeric plastic through a ceramic die opening and as extruded has an indefinite length in the machine direction, a controlled uniform thickness, and a width which is approximately 5 to 50 times or more the thickness. A preferred width to thickness ratio is about 30:1, or about 3 cm to 1 mm. The strap or tape may be cut to the desired length and partially embossed, serrated or scored either lengthwise or transversely to provide fracture or flex lines. The spacing of the serrations or score lines control the degree of flexibility or aggressiveness of the tool working face.

Abstract: A two honing process eliminates the need for subsequent brush honing at another location. The honing process which is accomplished with a single head uses rough honing stones or tools for the initial phase, and finishing tools of tightly compacted abrasive containing plastic monofilaments for the second phase. The phases may be contiguous, slightly spaced, or preferably overlap for up to about one-half of the rough honing phase. When the finishing honing tools are operating alone, the angle of movement of the tools is somewhat askew of the oil retaining ridges and grooves formed by the rough honing operation. With the process, the oil bearing surfaces have improvements in plateau finish and surface topography, avoid abrasive contamination caused by hard finishing tools, and obtain such improvements in a more economic manner.

Abstract: An extruded plastic strip contains abrasive grains or minerals embedded homogeneously therein throughout is scored along the machine or extrusion axis direction, such scoring including elliptical or pointed perforations with the long axis or generally pointed ends aligned with the scoring and parallel to the machine or extrusion axis. The preferred plastic material is a 612 nylon, although other plastics may be employed. The material is heat workable, yet relatively stiff and can be used to form a wide variety of power driven abrasive tools such as shown in applicant's prior application Ser. No. 07/471,385 filed Jan. 29, 1990 entitled "Abrasive Tool and Method of Making", now U.S. Pat. No. 5,155,945. The present application also discloses a rotary wheel type tool utilizing the perforated strip, and a method of making that tool using a gel type cyanoacrylate as an adhesive. With the strip of the present invention, rotary wheel tools as well as many other tools can economically be produced.

Abstract: A rotary finishing tool and a method for making the same characterized by a rolled or coiled strap of plastic material with abrasive homogeneously embedded throughout. The coiled strap is secured to the bottom interior surface of a cup element by a thin layer of liquid quick setting or instant adhesive. The strap may include transverse slits or serrations to provide the degree of flexure desired and/or to provide fracture lines. To make the tool, a longitudinally extending strap of an abrasive containing plastic material is heated and rolled along its longitudinal axis thereby forming a lightly coiled strap. A cup element is supported and the coiled strap is driven into the cup element whereby one end face of the coiled strap is driven into contact with a thin layer of the instant adhesive. Upon curing of the adhesive, the one end face is secured to the bottom interior surface of the cup element, and the opposite or outer end face becomes the working face of the tool.

Abstract: A plastic strap or tape having granular abrasive embedded homogeneously throughout is cut, shaped and formed into a variety of abrasive finishing tools. The plastic working element is preferably rather stiff 6/12 nylon and contains about 30 to 45% by weight of abrasive material. The strap or tape is formed by extrusion of such non-elastomeric plastic through a ceramic die opening and as extruded has an indefinite length in the machine direction, a controlled uniform thickness, and a width which is approximately 5 to 50 times or more the thickness. A preferred width to thickness ratio is about 30:1, or about 1 mm to 3 cm. The strap or tape may be cut to the desired length and partially embossed, serrated or scored either lengthwise or transversely to provide fracture or flex lines. The spacing of the serrations or score lines controls the degree of flexibility or aggressiveness of the tool working face.

Abstract: An extruded plastic strip contains abrasive grains or minerals embedded homogeneously therein throughout is scored along the machine or extrusion axis direction, such scoring including elliptical or pointed perforations with the long axis or generally pointed ends aligned with the scoring and parallel to the machine or extrusion axis. The preferred plastic material is a 612 nylon, although other plastics may be employed. The material is heat workable, yet relatively stiff and can be used to form a wide variety of power driven abrasive tools. The present application also disclosed a rotary wheel type tool utilizing the perforated strip, and a method of making that tool using a gel type cyanoacrylate as an adhesive. With the strip of the present invention, rotary wheel tools as well as many other tools can economically be produced.

Abstract: A plastic strip or strap having granular abrasive embedded homogeneously throughout is cut, shaped and formed into a variety of abrasive finishing tools. The plastic working element is preferably rather stiff 6/12 nylon and contains about 30 to 45% by weight of abrasive material. The strip or strap is formed by extrusion of such non-elastomeric plastic through a ceramic die opening and as extruded has an indefinite length in the machine direction, a controlled uniform thickness, and a width which is approximately 5 to 50 times or more the thickness. A preferred width to thickness ratio is about 30:1, or about 1 mm to 3 cm. The strip or strap may be cut to the desired length and partially embossed, serrated or scored either lengthwise or transversely to provide fracture or flex lines. The spacing of the serrations or score lines controls the degree of flexibility or aggressiveness of the tool working face.

Abstract: A rotary finishing tool and a method for making the same characterized by a rolled or coiled strap of plastic material with abrasive homogeneously embedded throughout. The coiled strap is secured to the bottom interior surface of a cup element by a thin layer of liquid quick setting or instant adhesive. The strap may include transverse slits or serrations to provide the degree of flexure desired and/or to provide fracture lines. To make the tool, a longitudinally extending strap of an abrasive containing plastic material is heated and rolled along its longitudinal axis thereby forming a lightly coiled strap. A cup element is supported and the coiled strap is driven into the cup element whereby one end face of the coiled strap is driven into contact with a thin layer of the instant adhesive. Upon curing of the adhesive, the one end face is secured to the bottom interior surface of the cup element, and the opposite or outer end face becomes the working face of the tool.