Improving Part Quality and Reducing Costs in Medical Grinding

In medical manufacturing, even small inconsistencies in components like implants, surgical tools, or drill bits can lead to costly failures and compromised safety. Precision and reliability aren't just goals—they're required for industry standards and FDA approval. Yet it’s common for manufacturers to struggle with persistent issues like inconsistent surface finishes, excessive burr formation, and unpredictable wheel performance that increase scrap and labor costs.

At Continental Diamond Tool (CDT), we understand the root causes behind these challenges and help medical manufacturers overcome them through targeted, reliable, custom engineered grinding solutions.

One of CDT’s biggest strengths is how closely our sales and engineering teams work together—often as the same people. Many of our team members serve dual roles, combining application expertise with customer-facing support, so the person helping you select your wheel also understands how to fine-tune it for maximum performance.

“The most important factor for medical suppliers is part quality,” says Blu Conrad, CDT Application Engineer who specializes in medical manufacturing support. ”When we see issues like burrs, poor finishes, or short wheel life, it’s usually a sign that there is a problem with the wheel or process set up. We can help you fix that.”

CDT’s vitrified CBN wheels provide reliable, repeatable performance when grinding complex medical components like surgical drill bits.

Is Your Grinding Process Hurting Your Productivity?

Do you face problems like:

• Inconsistent surface finishes and part quality?

• Excessive manual deburring labor due to excessive burr formation?

• Short wheel life and frequent dressing?

• Difficulties maintaining tight tolerances and precise geometries?

These problems often come down to using a grinding wheel or machine settings that are not optimized for your application. At CDT, we take a hands-on, data-driven approach to help you pick the right wheel and adjust your set up — so you can count on consistent, reliable performance that fits the way you work.

Specialized Grinding Wheels Designed for the Medical Industry

CDT specializes in designing, developing, and delivering custom-engineered diamond and cBN grinding wheels for all types of medical manufacturing. While we have seven unique product lines, there are three distinct grinding wheel types that we commonly specify for medical manufacturers:

• Plated Wheels: Perfect for roughing operations, plated wheels maintain precise profiles — like those required on complex medical implants and surgical cutting tools — for the entire life of the wheel with no dressing required. We also offer a strip and replate program that reuses your wheel core and reapplies the abrasive—restoring it to like-new condition at a fraction of the cost.

• Vitrified CBN Wheels: Often found in finishing operations, these wheels minimize burr formation and ensure consistent, high-quality results. Best used with machines featuring onboard wheel dressers, vitrified cBN wheels are particularly cost effective for manufacturers who are taking advantage of lights out operation. CDT also manufactures the onboard Diamond Rotary Dressers that keep these wheels efficiently grinding at peak performance.

• Hybrid Bond Wheels: A variation of CDT's resin bond grinding wheels, our EVO Hybrid Bond formula provides excellent shape retention, consistent free cutting, and reduced heat buildup. We often recommend this product line for finishing medical parts on machines where operators manually dress the wheel.

“We’ve helped customers reduce cycle times by up to 20%,” recalls Blu. “And just as important, we’ve been able to significantly cut down on manual deburring labor—especially when they switch to vitrified CBN wheels paired with onboard wheel dressers that run cleaner and cooler with less downtime than manual dressing.”

Proven Solutions Across Leading Machines and Materials

CDT grinding wheels are designed to perform on leading medical manufacturing machines, including platforms from Walter, Rollomatic, Schütte, Starr, and Strausak. Whether you're a large OEM or a contract manufacturer, we tailor each wheel to your production requirements.

“Medical components are often made from stainless steels like 17-4 or 455, which can be tricky,” Blu explains. “They’re gummy and prone to burrs. That’s why we pay close attention to both the material and the machine setup when we spec a wheel.”

Our team takes material properties—such as ductility and hardness—into account when developing wheels. Stainless steels are particularly prone to heat buildup and burrs. With the right wheel and setup, we can significantly reduce these effects, helping customers reduce scrap and minimize secondary deburring processes.

Your Trusted Guide for Long-Term Success

CDT isn't just a wheel supplier; we're your strategic partner in precision grinding. Our team proactively collaborates with you from new product prototyping to established production optimization, ensuring your processes are finely tuned and continuously efficient. 

We can also help you evaluate machine options—well before it's time to order your grinding wheel. “It’s more common than it should be for us to get called in after a machine is already purchased,” says Blu. “We love to be part of the conversation earlier because features like onboard dressers make a huge difference. We’ve had customers retrofit onboard dresser technology just to unlock the full performance of a vitrified CBN wheel.”

In addition, our grinding lab is a valuable resource for customers. They can safely explore the performance limits of their wheels and identify opportunities for improvement without interrupting production or incurring the cost of scrap and downtime. We also offer a portable lab to diagnose system inefficiencies directly at the production site.”

From implants to surgical tools, CDT Application Engineer Blu Conrad specializes in helping medical manufacturers improve precision, reduce scrap, and save time. Reach out today.

Why Medical Manufacturers Trust CDT

Medical manufacturers consistently choose CDT because we deliver:

• Rapid turnaround and reliable lead times

• Dependable quality, performance, and cost-efficiency

• Hands-on technical support, troubleshooting, and training for your operators

• Expert R&D engineering services focused on helping you succeed

Don’t let grinding wheel issues compromise the quality or productivity of your medical manufacturing operations. Take control of your process and partner with CDT to confidently meet your critical manufacturing goals.

Ready to transform your grinding process? Contact Blu Conrad and others on the CDT sales team today for a free consultation and quote. Call 1-800-443-6629 or visit our webform to get started.

CDT Targets Growth in Eastern Europe with Sales Presence in Poland

Continental Diamond Tool is targeting major sales growth in Eastern Europe after launching our first sales force in Poland.

Leading the team is Mariusz Kowalski, our new Sales Manager for Poland, who is spearheading a drive for new orders on behalf of Continental Diamond Tool (CDT).

CDT supplies precision tooling for Tier 1 aerospace and automotive companies, specialising in designing and producing high‑spec grinding wheels for advanced manufacturing processes. Our product range includes diamond‑encrusted rotary dressers, accurate to within one‑thousandth of a millimetre.

We have also ramped up the manufacture of new electroplated grinding wheels and tools thanks to a £250,000 investment in cutting‑edge equipment at our Kinmel Bay location.

CDT sees huge opportunities to supply new customers in the rapidly developing engineering sector in Poland and other Eastern European countries.

The move is part of a £4 million expansion that will triple production and double our workforce in Kinmel Bay to 80.

As part of the strategy, we will move later this year to a new 30,000 sq ft factory—three times the size of our current premises—less than half a mile away on the Tir Llwyd Industrial Estate.

Mr Kowalski graduated with a Master of Science from Warsaw University of Technology, specialising in Mechatronics Engineering, which combines mechanical, electrical, computer engineering and robotics to create innovative and complex systems.

Before joining CDT he spent most of his career at Fanar, a Polish leader in machining‑tool manufacturing, where he rose through the ranks and developed new grinding and welding processes.

Now representing CDT from Łomianki—about 20 miles west of Warsaw—he said:

“The new plant in Kinmel Bay will generate more products and a larger production volume, putting us in a perfect spot to support what’s happening here in Poland.

“The Polish market in terms of advanced manufacturing in particular is the fastest-growing in Europe with aerospace companies like Pratt and Whitney and General Electric already in Poland and the country has its own rapidly growing engineering sector which we can service.

“Poland is also attractive to European Union countries like Germany and France because it has a well-educated and skilled workforce, lower costs and is more flexible.

“It also has between 30 and 40 tool-making companies and that’s a market we are also focusing on along with the automotive sector.

“Poland has a lot of engineering companies popping up every day and they’re growing fast.

“I believe that in 10 years’ time Poland could be a world leader in high tech for aerospace, automotive and the medical science industries and CDT can be part of that.

“With our modern factory in Kinmel Bay due to come on line later this year and our operation in the USA in five years’ time we could be looking at a market worth £80 million to the company.

“It is early days for us here in Poland but every day we learn more and make new contacts.

“It’s a fast developing country. Twenty years ago we had 20 per cent unemployment but now it’s below five per cent and the economy is booming.”

CDT’s European division is also seeing business boom, with sales of our new electroplated grinding products rocketing by 960 per cent over the past two years.

We expect electroplated products to outsell rotary dressers within a few years as orders continue to increase, and the move into Poland should only boost demand.

We already export 50 per cent of our turnover from the U.K., with electroplated grinding products reaching beyond Europe into the Middle East, Thailand and Indonesia, and sales forecast to overtake rotary dressers in two to three years.

The Kinmel Bay operation was founded as Consort Precision Diamond in 1984, specialising in diamond‑encrusted rotary dressers and grinding wheels.

CDT acquired and rebranded the business in 2018; our global headquarters are in New Haven, Indiana.

We are one of only two similar companies in the U.K., supplying sectors that include aerospace, automotive, medical and semiconductors.

Our products are used in Boeing 777 and 787 Dreamliner aircraft, as well as the Airbus A330–A380 range, whose wings are made at the Airbus factory in Broughton, Flintshire.

Managing Director Jeff Wirth said:

 “Strategically, appointing the team in Poland was a very important move because it’s the next step in our expansion in Europe.

“Poland’s economy has been transformed in recent years and it’s now a manufacturing powerhouse so this is perfect timing.

“For many years Germany was the engine of Europe and now Poland has taken that mantle.

“Poland is booming and growing. They have a great workforce and a great work ethic and the investment they have made over the past 20 to 30 years has paid off.

“Our operation there is being integrated into the company at a time when we are going to be moving into the new factory which will enable us to triple our production capacity, with new products coming on stream.

“Mariusz will be at the forefront, ensuring that our clients in Poland receive top-notch service and support. His expertise and dedication are key to navigating this phase of growth.

“It’s a really exciting time for CDT – watch this space.”

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Continental Diamond Tool Limited (CDT Ltd.), based in Kinmel Bay, Rhyl, U.K., is the European subsidiary of Continental Diamond Tool Corporation, headquartered in New Haven, Indiana, U.S.A. For more than 40 years, CDT Ltd. has been a leader in diamond rotary dresser technology, originally operating as Consort Precision Diamond. Since joining CDT, the company has expanded its product line, delivering high-performance diamond plated grinding wheels and other premium superabrasive products to customers worldwide.

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Related links:

https://north-wales-business.co.uk/high-flying-north-wales-engineering-firm-targets-growth-in-eastern-europe/

https://www.welshnewsextra.com/high-flying-north-wales-engineering-firm-targets-growth-in-eastern-europe/

https://www.baysideradio.co.uk/news/north-wales-engineering-firm-targets-growth-in-eastern-europe-10501

https://www.insidermedia.com/news/wales/precision-engineering-firm-makes-appointment-to-boost-growth-in-eastern-europe

https://www.business-live.co.uk/enterprise/north-wales-precision-engineering-firm-31694121

https://www.rhyljournal.co.uk/news/25181361.north-wales-firm-eyes-huge-growth-eastern-europe/

https://www.wales247.co.uk/high-flying-north-wales-engineering-firm-targets-growth-in-eastern-europe

https://businessnewswales.com/north-wales-engineering-firm-targets-growth-in-eastern-europe/

Celebrating Our Apprentices

CDT Ltd.'s current and former interns (left to right): Corey Lloyd-Jones, Joe Bowles, Stephanie Hughes-Jones, Daniel Hughes-Jones, and Rhys Butler.

Investing in the Future: Celebrating Our Apprentices for National Apprenticeship Week

At Continental Diamond Tool (CDT), we take great pride in nurturing the next generation of engineers through our apprenticeship programs. In celebration of National Apprenticeship Week in the U.K., we’re highlighting the inspiring journeys of five apprentices at our manufacturing center in Wales. Read on to see how these talented individuals have developed their skills, grown within the company, and are shaping the future of engineering.e.”

From Apprentice to Supervisor – Joe Bowles’ Journey

Joe Bowles began his career with Continental Diamond Tool Ltd. in September 2007 as an engineering apprentice. Over the years, his dedication and willingness to learn saw him progress into new roles, gaining invaluable experience along the way. Today, he is the Supervisor of the Grinding Department, where he leads a skilled team and ensures high standards of quality and precision.

Reflecting on his journey, Joe shares:

"From an apprentice 17 years ago to a supervisor, my path has been driven by hard work and the support of a company that values growth, innovation, and investment in people. I look forward to furthering my career with CDT and being part of its bright future."

Joe’s success is a testament to the long-term benefits of apprenticeships, illustrating how they can open doors to leadership and career progression.

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Daniel Hughes-Jones – A Key Player in CNC Machining

Daniel joined CDT Ltd. in March 2021, quickly making an impact in the CNC Machining Department. He successfully completed his HNC in Engineering, further strengthening his knowledge and technical expertise. Now, as a key team member, he operates multiple CNC machines and plays an important role in training new apprentices.

"My apprenticeship at CDT provided me with vital knowledge and a developed skill set, and I’m grateful to pass on my knowledge and experiences to the next generation of apprentices." – Daniel Hughes-Jones

Daniel’s ability to mentor new apprentices showcases the value of experienced employees sharing their knowledge, ensuring a strong and skilled workforce for the future.

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Corey Lloyd Jones – Building a Strong Foundation

Corey started his apprenticeship with CDT Ltd. in September 2023 and is currently in his second year, working towards his HNC in General Engineering while also completing a Level 3 NVQ. With a strong ambition to learn, Corey is eager to develop his expertise across multiple machines and broaden his engineering knowledge.

"After finishing my apprenticeship, I would like to progress further within the company and learn more skills on more machines. I chose this career path as it looked like a good challenge. I am doing the general engineering HNC course because it opens up a lot of opportunities for me in the future, rather than having just mechanical or electrical HNC." – Corey Lloyd Jones

Corey’s enthusiasm for engineering showcases how apprenticeships provide a solid foundation for career growth, allowing young professionals to tailor their learning to suit their ambitions.

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Rhys Butler & Stephanie Hughes-Jones – The Next Generation of Engineers

Rhys Butler and Stephanie Hughes-Jones, Daniel’s younger sister, are the newest members of CDT Ltd.’s apprenticeship program, having joined in September 2024. Though early in their careers, both are already embracing the challenges and opportunities that come with learning on the job.

Rhys shares his thoughts on his apprenticeship so far:

"I've been on my apprenticeship for around seven months now, and I've thoroughly enjoyed it because it has provided hands-on experience, and a deeper understanding of how complex systems come together. The opportunity to apply theoretical knowledge in real-world settings has been both challenging and rewarding. I've gained valuable skills in problem-solving, teamwork, and technical expertise, which have made me more confident in my abilities. Looking ahead, I would love to further develop my expertise in engineering and continue to grow in a role where I can contribute to impactful projects." – Rhys Butler

Stephanie, who was drawn to engineering for its balance of hands-on work and intellectual challenge, shares her experience:

"I chose engineering because I like jobs that are both physically challenging and mentally interesting. My apprenticeship helps me improve my skills as a machinist while giving me chances to keep learning and growing." – Stephanie Hughes-Jones

Their journeys emphasize how apprenticeships provide real-world experience, technical expertise, and career-building opportunities from day one.

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Apprenticeships are more than just training—they’re a launchpad for a successful career. They provide a solid foundation for career progression, hands-on experience, and the opportunity to develop vital skills in a fast-paced, innovative environment.

The apprentices above are prime examples of what can be achieved through dedication, hard work, and the right support. From those just starting out to those who have grown into leadership roles, their journeys highlight the value of apprenticeships and the opportunities they create.

👉 Interested in an apprenticeship or know someone who is? CDT Ltd. works closely with Coleg Llandrillo to identify promising candidates for our highly competitive engineering apprenticeship programme. Each year, we offer placements to 2 to 3 students. The next apprenticeships will begin in September 2025. If you’re interested, we encourage you to explore Coleg Llandrillo’s Engineering Programme as the best route to be considered for a future opportunity with us. Learn more about Coleg Llandrillo here: https://www.gllm.ac.uk/

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Continental Diamond Tool Limited (CDT Ltd.), based in Kinmel Bay, Rhyl, U.K., is the European subsidiary of Continental Diamond Tool Corporation, headquartered in New Haven, Indiana, U.S.A. For more than 40 years, CDT Ltd. has been a leader in diamond rotary dresser technology, originally operating as Consort Precision Diamond. Since joining CDT, the company has expanded its product line, delivering high-performance diamond plated grinding wheels and other premium superabrasive products to customers worldwide.

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Global Growth and Local Jobs Spurred by Cutting Edge Investments at Kinmel Bay Facility

Cllr Nigel Smith (left), Conwy Council’s Cabinet Member for Sustainable Economy, visits with Production Manager Justin Hughes (right), showcasing one of the precision-engineered tools made possible by our new cutting-edge equipment, funded in part by the UK Shared Prosperity Fund secured with the help of Conwy Council.

A precision engineering company in North Wales is gearing up for global growth by investing £250,000 in cutting edge equipment.

Recruitment is also underway at Continental Diamond Tool (CDT) in Kinmel Bay as part of an ambitious expansion plan that will create 40 new jobs.

It’s all preparation for a move next year to a 30,000 sq ft factory nearby that’s three times the size of the current premises on the Tir Llwyd Industrial Estate.

Overall, the firm’s Indiana-based American owners, who took it over six years ago, are pumping £4 million into the company to triple production capacity and start making new products.

The niche company specialises in the manufacture of diamond-encrusted rotary dressers and grinding wheels, with tolerances of down to 1,000th of a millimetre in terms of accuracy.

It’s one of only two similar outfits in the UK and supplies a range of manufacturing sectors, including aerospace, automotive, medical and semi-conductors.

The company’s customers include blue chip corporations like Rolls Royce and Tenneco, with more than 60 per cent of the products being exported.

According to the loyal workforce, the investment is the “perfect present” for the company that’s celebrating its 40th anniversary this year.

It was also music to the ears of Cllr Nigel Smith, Conwy Council’s cabinet member for Sustainable Economy, who is one of three councillors who represent Kinmel Bay on the authority.

The council helped CDT secure £100,000 in funding from the UK Shared Prosperity Fund towards the cost of the new equipment.

He came on a visit to see how the money had been spent on “space age kit”, including a  high tech machinery centre, lathe and inspection equipment.

Cllr Smith said: “What they do is very impressive, both in terms of the state-of-the-art technology and the high skill employment they provide in Kinmel Bay.

“It’s fantastic that they’re selling their world-leading products to an international market and they have a raft of blue chip customers like Rolls Royce.

“Over the years there has been a good relationship between the company and the council’s business development team and long may that continue.

“We were delighted to be able to help in securing £100,000 towards the cost of these cutting edge machines. 

“It’s impressive, top-of-the-range technology and the level of precision they work to is mind-boggling – their tolerances are within microns. It’s engineering of the highest pinnacle.

“With them moving now to larger premises, I’ll be speaking to our team if there is anything more we can do to help them moving forward to help them grow and expand.

“Employment is a key issue in Conwy so have foster and support business where we can to retain our young people.

“It’s good to see the emphasis on training here and the apprenticeships, helped by the fact that they have a very good relationship with the local college.

“It’s always been a great company and there is now a new momentum under the American ownership and it’s very pleasing to see them invest in Kinmel Bay and that will pay dividends. 

“The excellent legacy of the original company is now being turbo-charged by the Americans.

“It’s a company with ambition and it’s plain to see how committed the team are here – everybody has a good work ethic and it bodes very well for the future.”

Cllr Smith’s visit was hosted by Production Manager Justin Hughes, whose father was one of the founders of the original company, Peter Hughes.

Justin said: “In this latest investment we have spent £250,000 on the three machines and it’s well in excess of £1 million just on new equipment in the last two or three years.

“We’re very grateful to Conwy Council for their help in facilitating the £100,000 that’s come from the UK Shared Prosperity fund. It’s made a massive difference because it enables us to employ the people to use those machines.

“The skill required by the people we have to do that is of the highest order and is just as important as the machine.

“Training and developing those people is just as key as our processes and our high precision machinery so working with the engineering centre at the local college is a big help.

“I am immensely proud of the company’s legacy and the way things are moving forward. It’s in my blood, this company.

“These are really exciting times with the move to the larger premises which will enable us to have new product lines.

“Continental Diamond Tool are the third biggest superabrasives supplier in the USA and they are looking to become the biggest. 

“The American side of the business is growing at a rate of 30 per cent a year and we are the European arm and they are looking to us to emulate that success over here. 

“We are developing a name for ourselves against the big multi-national household names and we are becoming one of those names.

Finance Manager Michaela Lawton added: “The expansion into the new premises will enable us to increase capacity and the number of products we make so the sky is the limit.

“All this is happening in the year we are celebrating our 40th anniversary and the American side of the company is celebrating its 50th.

“We’ve got a great team of people here and there’s a shared pride in what we’re achieving.

“The expansion will create another 40 jobs and we have started to recruit people because of the skill sets required and the time it takes to train them. 

“We’ve had a steady number of new employees joining us, particularly over the last four or five months so we can get all our ducks in a row.

“We make our products to 1,000th of a millimetre in terms of accuracy so we have to conduct the whole operation with the same level of exceptional quality.”

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Related articles:

https://www.herald.wales/north-wales/conwy/global-growth-will-take-off-with-cutting-edge-kit-helping-to-create-new-40-jobs/

https://www.rhyljournal.co.uk/news/24752773.north-wales-firm-create-40-jobs-part-expansion/

https://www.insidermedia.com/news/wales/engineering-firm-targets-global-growth-with-investment-in-new-equipment-customers-include-rolls-royce-and-tenneco

https://www.baysideradio.co.uk/news/global-growth-will-take-off-with-kit-helping-to-create-40-jobs-9750

https://north-wales-business.co.uk/global-growth-will-take-off-with-cutting-edge-kit-helping-to-create-new-40-jobs/

https://businessnewswales.com/engineering-firm-invests-in-expansion-plan-and-creates-new-40-jobs/

https://www.welshnewsextra.com/global-growth-will-take-off-with-cutting-edge-kit-helping-to-create-new-40-jobs/

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Evaluating and Optimizing Cutting Performance in Grinding Operations

Grinding wheels are critical tools in many forms of manufacturing for cutting, shaping, and finishing materials. In this blog, we’ll explore the methods for evaluating cutting performance as detailed by CDT Senior Application Engineer Chad Wesner in Episode 9 of The Grinding Chronicles. Whether you’re using CBN grinding wheels, diamond grinding wheels, or conventional abrasive grinding wheels like aluminum oxide or silicon carbide, optimizing cutting performance is essential for staying competitive.

Watch the video or read the article below to learn how to evaluate grinding wheel performance and make data-driven decisions to improve your grinding operations.

The Grinding Chronicles - Episode 9

Cutting Performance: The Key Metrics to Measure

In The Grinding Chronicles, Chad Wesner, Senior Application Engineer at CDT, outlines the structured process our engineers use for evaluating the cutting performance of grinding wheels. This process involves three key steps: collecting data, processing data, and evaluating the results. Each step builds on the next to provide an effective means of comparing the performance of different wheels, whether CBN, diamond, or conventional abrasive.

1. Collecting Data

The first step is collecting the necessary data from the grinding process. For an accurate evaluation of cutting performance, you’ll need to use the following instrumentation:

• Power Meter: Attach a power meter to the grinding wheel spindle to measure the power consumed during the grinding process.

• Data Acquisition Device (DAQ): The power meter connects to a DAQ, which records the data from the grinding operation.

• Digital Signal Processing (DSP): Export the collected data into a DSP system for further analysis.

This data forms the foundation for assessing grinding wheel performance for comparison with different wheel types or other variables.

2. Processing Data

After data collection, the next step is processing the information to obtain two critical metrics: Specific Power and Specific Grinding Energy.

• Specific Power: Start by plotting a graph of spindle power vs. time during the grinding process. The power meter collects measurements while grinding the workpiece at various material removal rates. To calculate Net Grinding Power, subtract the idle spindle power from the steady state grinding power. Repeat this process multiple times at different material removal rates, and plot the results to create a graph of specific power.

• Specific Grinding Energy: This metric represents the amount of energy required to remove a specific volume of material. Similar to specific power, the spindle power vs. time graph provides the total energy in Joules. To calculate Specific Grinding Energy, divide the total energy by the volume of material removed, yielding a value in Joules per cubic millimeter.

These two metrics allow you to compare the cutting efficiency of different grinding wheels and make informed decisions about which wheel performs best for your application.

3. Evaluating Data

Once the data is processed, the final step is to evaluate the cutting performance of the grinding wheels. By examining the graphs of data for Specific Power and Specific Grinding Energy, you can identify which wheel delivers better performance.

In The Grinding Chronicles video, you can see in our graph that the wheel represented by the blue line had the best cutting performance because it had the lowest power per material removal rate. In the next graph, we can see that the wheel with the lowest Specific Grinding Energy was more free-cutting, indicating greater efficiency and reduced energy consumption during the grinding process.

Taking Your Grinding Operations to the Next Level

Evaluating cutting performance is an essential part of optimizing grinding processes, whether you're using superabrasive grinding wheels or conventional abrasive wheels. By measuring Specific Power and Specific Grinding Energy, you can compare wheel performance, make informed decisions, and fine-tune your grinding operations for better efficiency and quality.

At Continental Diamond Tool, we have a team of application engineers that specialize in helping our customers with this type of analysis. If you're looking for more help with common grinding problems and their remedies, or need assistance optimizing your cutting performance, contact CDT’s engineering team at TheGrindingChronicles@cdtusa.net.

By following these evaluation methods and choosing the appropriate grinding wheel for your material, you can achieve superior cutting performance and enhance the efficiency of your grinding process.

Emphasis on Outstanding Customer Service at Continental Diamond Tool

At Continental Diamond Tool (CDT), customer service isn’t just a department—it’s the core of our entire operation. From the moment a customer reaches out with an inquiry to the final delivery of the product, CDT ensures that every interaction reflects our commitment to quality, collaboration, and satisfaction. Our expert sales team, fast response times, and innovative technical solutions come together to create an outstanding customer experience at every step. Watch the video or read the article below to learn more.

Putting the Customer First

"Everything we do is centered around ensuring that the customer comes first," says Erik Van Meter, Senior Product Manager of Conventional Abrasives at CDT. This philosophy shapes the day-to-day operations of every department. Whether it’s processing quotes, collaborating with engineers, or ensuring timely delivery, CDT’s entire focus is on taking care of the customer.

At CDT, we understand that every customer has unique needs. Whether they are an aerospace company seeking specialized grinding tools or a medical device manufacturer looking for precision and reliability, we treat each client with the same level of attention and dedication. We take pride in offering high performance grinding solutions that are not only effective but also tailored to their specific challenges

Simplifying the Process

A seamless customer experience begins with a streamlined process. According to Jeff Gongaware, CDT’s Customer Service Manager, "The process of getting a quote from CDT couldn’t be any easier." At CDT, customers can inquire via phone, email, or through our website, making it convenient and flexible to begin the process. Once a quote is approved, we provide an acknowledgment within 24 hours, ensuring that communication is prompt and clear.

This quick turnaround is a point of pride for CDT. "One of the things I always hear at CDT is how fast we get our quotes back to our customers compared to our competitors," says Matt Harnish, one of CDT’s dedicated sales representatives. In today’s fast-paced manufacturing environment, time is of the essence, and CDT’s ability to provide quick, accurate quotes sets us apart from the competition and builds strong relationships with our customers.

Real-Time Solutions for Real-World GRINDING Challenges

Our commitment to customer satisfaction goes beyond providing fast quotes on high-quality tools — we also work hand-in-hand with our customers to develop solutions that address their specific needs. As Blu Conrad, CDT’s Application Engineer, explains, "In our facility, we have our own grinding lab with machines dedicated to R&D and prototyping." This allows customers to test out solutions and adjust their parameters without downtime, all with CDT’s extensive expertise to guide the process.

In addition to offering product testing at our facility, CDT provides on-site support for customers facing unique challenges. "If they have a specific challenge that they can't solve on their own, an application engineer can go to their facility and spend whatever time is needed to work directly with their operators and engineers," says Blu. This personal approach ensures that CDT’s customers not only receive the tools they need but also the support to optimize those tools in their own production environments.

A Collaborative Approach to GRINDING WHEEL DESIGN

At CDT, we believe that teamwork makes all the difference. "At CDT, there are no silos," Erik notes. "Each department within the organization works together to ensure that the customer needs are met." This collaborative spirit ensures that whether a customer is interacting with sales, engineering, or production, they receive the same level of care and attention throughout their journey with CDT.

This culture of collaboration is key to maintaining fast response times, high-quality service, and long-lasting relationships. From quoting to production to delivery and support, each department at CDT works in unison to ensure that every order is fulfilled efficiently and to the highest standards. This teamwork fosters a work environment where our employees are empowered to share ideas, solve problems, and take pride in our customers’ success.

GRINDING Expertise That Makes a Difference

Behind every solution is a team of experts who bring years of experience to the table. Whether it’s solving complex grinding issues or fine-tuning product specifications, CDT’s team has the knowledge and expertise to help customers overcome any challenge. "With my 23 years of experience in grinding, I can help give customers a new perspective on facing their challenges," Blu shares. His expertise, combined with the know-how of CDT’s wider team, ensures that our customers are never alone in their search for the right solution.

Jeff adds, "What it takes to be successful in customer service at CDT is a positive attitude, product knowledge, and some problem-solving." These qualities are essential in guiding customers through the entire process, from initial inquiries to product delivery. CDT’s team not only knows the right questions to ask but is also skilled at offering insights and recommendations that help customers arrive at the best solution for their needs.

Personalized, Efficient Service

One of the key benefits of working with CDT is our personalized approach. "Every one of our tools is engraved with a specific W number," Jeff explains. "You can call us with that information, and we can go back and pull all the manufacturing specifications from the last time we made it." This system allows us to quickly and efficiently handle reorder requests, ensuring that customers receive the same high-quality tools they’ve come to rely on.

At CDT, we recognize that our customers are not just looking for products; they are looking for solutions that will help them succeed long term. By focusing on quick response times, personalized service, and expert problem-solving, we deliver not just tools but peace of mind.

Diverse Customer Base, Unique Solutions

Working with a diverse customer base presents unique challenges and opportunities. For Matt, the variety of customers makes the job exciting. "What I love about working at CDT is the wide range of customers that I get to deal with on a day-to-day basis. I’ve got boat manufacturers, medical companies, and those crafting airplane engines," Matt says. As a custom solutions provider of superabrasive tools, every product is unique and every design is tailored to meet the specific needs of our customers.

Whether we are working with customers in the medical field or in aerospace, we take the time to understand their individual needs. This tailored approach ensures that each customer gets exactly what they need to thrive in their respective industries.

Above and Beyond

At Continental Diamond Tool,  our commitment to customer service is evident in everything we do. From the first inquiry to ongoing support, we prioritize our customers’ success through collaboration, innovation, and expert guidance. As we continue to grow and expand, we remain focused on delivering the exceptional service and high-quality products that our customers have come to expect.

By working with CDT, customers gain access not only to cutting-edge tools but also to a team of dedicated professionals who are always ready to go the extra mile. Contact our sales team today at cdtusa.net/contact.

CDT Ltd. Unveils £4m Expansion Creating 40 New Jobs

From left: CDT Ltd. Managing Director Jeff Wirth, Finance Manager Michaela Lawton, General Manager Troy Giacherio, Production Manager Justin Hughes, President of Sales Shane Vardaman, and Director Nick Viggiano stand outside the 30,000 sq. ft. factory that the North Wales operation will soon be occupying.

A fast-growing precision engineering firm has announced a £4 million expansion plan that will double the workforce at its North Wales operation by creating 40 new jobs and triple production.

The investment by the American owners of Continental Diamond Tool (CDT) will include moving to a 30,000 sq ft factory that’s nearly three times the size of its current premises in Kinmel Bay and is less than half a mile away on the Tir Llwyd Industrial Estate.

The move is being hailed by staff as the “perfect birthday present” for the North Wales operation which is celebrating its 40th anniversary this year, having been founded as Consort Precision Diamond in 1984, specialising in the manufacture of diamond-encrusted rotary dressers and grinding wheels.

The niche outfit – still one of only two similar companies in the UK – supplies a range of manufacturing sectors, including aerospace, automotive, medical and semi-conductors.

Its products are used in Boeing 777 and 787 Dreamliner aircraft, as well as the Airbus range A330-A380 whose wings are made at the giant Airbus factory in Broughton in Flintshire.

The firm was taken over and rebranded in 2018 by CDT which has its headquarters in New Haven, Indiana.

News of the investment was delivered by company President Nick Viggiano, during his visit to the Kinmel Bay site, along with Shane Vardaman, CDT’s President of Sales.

The bigger factory will enable the company to increase the range of products they make, adding several new types of high precision grinding wheels.

Nick Viggiano said: “Things have worked out even better than I thought and the investment is a real big vote of confidence in the workforce here because they have a similar work ethic  and there’s good camaraderie between everyone.

“We expect to be three times the size we are in a few years’ time because there is a very big market for the products we are going to bring over here. 

“We expect a swift ramp-up. Given our extensive expertise with these products in the States, we can help the team over here to quickly hit the ground running.

“The new building is like a blank canvas so we can set everything up exactly the way we want, so we’re very excited about it.”

It was as sentiment endorsed by the American Managing Director, Jeff Wirth, who said: “This investment has been a long time coming, with six years of preparation and teambuilding leading up to this moment.

“Our Kinmel Bay team, known for their rotary dressers, has already started producing electro-plated products on a small scale.

“Moving to the new building that’s nearly three times the size will give us the space to expedite that process. Additionally, we plan to manufacture two vitrified products and a hybrid product in the new space.

“This is a big step and it goes hand in hand with the expansion we’re doing in the United States.

“It comes down to Nick having a belief in the people and the team. This is going to put rocket boosters under the company to continue with the growth trajectory.

“With everything consolidated under one roof, we will get to lay it out to maximise efficiency instead of having to work around the nooks and crannies of the current building.

“The accommodation will also be improved for the employees with nice fresh locker rooms and a cafeteria.

“Nick has a supercharged, can do mentality and we expect to be up and running in the new building in the first quarter of next year.”

According to Finance Manager Michaela Lawton, the Kinmel Bay staff  were delighted to have the opportunity to finally meet Nick and Shane in person.

She said: “We have a solid leadership team here and a fantastic workforce that has the full backing of our American owners and it’s clear that the team here has proved itself worthy of this massive investment.

“It’s going to be a process over the next few years, with recruitment, upskilling and training and a lot of capital expenditure on fitting out the new factory with the specialist equipment that we need.

“We are aiming to follow in the footsteps of our American counterparts who have seen huge growth over the last 10 years.

“They’ve gone from our current size to employing over 200 people and we want to follow the same path.”

Justin Hughes, the production manager in Kinmel Bay, has worked at the Kinmel Bay site for 17 years and is the son of the retired technical director, Peter Hughes, who was among the founders of Consort Precision Diamond.

He said: “The takeover has been a marriage made in business heaven because the operations on both sides of the Atlantic dovetail perfectly with each other.

“The news about the investment is incredibly exciting and is the perfect birthday present as we celebrate our 40th anniversary.

“It will undoubtedly inspire us to reach even greater heights and become a truly global player. The sky really is the limit.”

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Related articles:

Kinmel Bay firm to double workforce with £4m expansion - Rhyl Journal

Advanced manufacturer Continental Diamond Tool in new larger factory investment creating 40 jobs - MSN

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Harnessing the Power of a Grinding Lab

When it comes to grinding, the first step in overcoming your challenges is gaining a clear, data-driven understanding of your process. Episode 2 of The Grinding Chronicles, hosted by CDT Application Engineer Harrison Sheldon, shows how using objective data from a grinding lab can significantly improve your process. Watch the video or read on to discover how CDT’s Grinding Lab can help you transition from subjective assessments to actionable insights.

The Grinding Chronicles - Episode 2

Making Sense of the Complex Grinding Process

Grinding is one of the most complex machining processes, involving more variables than most. Traditionally, operators have relied on their senses—sight, sound, and feel—to measure performance. While this may have worked in the past, it introduces subjectivity into the process. No two operators experience grinding in exactly the same way, leading to inconsistencies and inefficiencies. That’s where a grinding lab steps in, providing a more reliable and consistent way to measure performance.

Data-Driven Optimization

At CDT, we believe in using objective data to optimize grinding processes, and our Grinding Lab is at the forefront of this approach. The lab uses a variety of sensors to collect data across four key categories: cut, wear, quality, and cost. By focusing on these areas, we are able to make informed decisions that directly improve performance and efficiency.

Here’s how we break it down:

• Cut: The way a grinding wheel cuts is one of the most critical factors in overall performance. In our lab, we focus on three specific variables that help us understand how efficiently a wheel cuts: power, force, and vibration. Power is the energy input to the grinding process, while force reflects the mechanical effort required for material removal. Vibration is a crucial indicator of smoothness and stability in the grinding operation. By collecting data on these variables, we can ensure that the wheel is cutting at its optimal capacity.

• Wear: Wear is an inevitable part of any grinding process, but controlling and understanding it is essential for maximizing efficiency. In our Grinding Lab, we use precise measurement techniques to run the wheel through a test coupon, giving us an exact rate of wear. This data allows us to optimize wheel life, reducing the frequency of wheel changes and improving productivity.

• Quality: Quality is paramount in grinding, and factors like surface finish and burn must be closely monitored. Burn, for example, is a sign that the grinding process is too aggressive, potentially damaging the workpiece. By measuring surface finish and detecting burn, we ensure that the grinding process meets the high standards required by manufacturers without sacrificing quality.

• Cost: In any manufacturing process, cost is a key consideration. Our lab calculates the cost of running the grinding wheel under various conditions, allowing us to find the most cost-effective solution. Whether it’s reducing power consumption, minimizing wear, or improving quality, we aim to optimize processes to deliver the best possible performance at the lowest cost.

Optimizing Your Process

Once we have collected data from the four categories—cut, wear, quality, and cost—we begin the process of optimization. By adjusting key variables, such as wheel speed, we can examine how changes impact the overall performance of the grinding process.

For example, in a recent test we compared two different wheel speeds: 14 meters per second and 24 meters per second. At the higher speed, the system produced more energy, but this came at a cost—burn was observed on the surface of the workpiece. On the other hand, the slower speed resulted in no burn and delivered a smoother surface finish. By analyzing these results, we were able to determine that the slower speed was a better option for both quality and cost-efficiency in that specific scenario.

This is the true power of our data-driven approach. Rather than relying on guesswork or subjective measures, we generate detailed, actionable insights that allow us to make informed decisions. These insights help us to improve efficiency, extend tool life, and reduce operational costs for our customers.

Bringing the Lab to You

One of the unique advantages of CDT’s Grinding Lab is its portability. We understand that every production environment is different, and the conditions in a controlled lab might not perfectly reflect the realities of your facility. That’s why we offer the option to bring our Grinding Lab directly to your site.

Using portable sensors and equipment, we can set up quickly and begin collecting data on your production machines. In as little as an hour, we can install the sensors, return the machines to operation, and start gathering valuable data. This allows us to analyze your specific grinding process in real time, helping you make immediate improvements without needing to transport your equipment or materials to an offsite location.

Whether you are developing a new grinding process or optimizing an existing one, CDT’s portable Grinding Lab offers a fast and effective way to gain insight into your operations.

Why Use a Grinding Lab?

The value of using CDT’s Grinding Lab lies in the objective, reliable data it provides. Unlike subjective measures, which vary from one operator to another, data from the lab is consistent, accurate, and easy to analyze. This data allows us to make informed decisions that improve efficiency, reduce costs, and enhance quality.

By measuring key variables such as power, force, and vibration, we are able to identify areas where performance can be improved. This level of precision is simply not possible with traditional observation methods. The end result? A more efficient, cost-effective grinding process that delivers consistent, high-quality results.

Get in Touch

Are you ready to take the first step toward solving your grinding challenges? Let CDT’s Grinding Lab help you move beyond guesswork and into the world of data-driven optimization. Email us at thegrindingchronicles@cdtusa.net to find out how we can help you develop or optimize your grinding process.

Check out more episodes of The Grinding Chronicles on our YouTube channel, where we continue to explore innovative solutions to your grinding challenges.

And remember, at CDT, we believe in the power of data to drive performance. Be sure to hit like, follow, and subscribe to our channels to stay up to date on our latest insights and updates!

CNC Machining vs. Traditional Machining: A Comparative Analysis for Precision Grinding Tools

When it comes to the manufacture of high-precision grinding wheels in diamond or cBN (Cubic Boron Nitride), the choice of machining method can significantly impact the quality and efficiency of production. At Continental Diamond Tool (CDT), we leverage traditional machining, CNC (Computer Numerical Control) machining, and automated robotic CNC machining to deliver high-precision grinding tools for many global industries. Having a skilled workforce and modernized equipment in all three types of machining is a distinct advantage for us and our customers. 

In this article, we will compare the pros and cons of these machining methods. You’ll learn how we incorporate all three into our manufacturing process to get the highest quality and most cost-effective results for our grinding tools and wheels. Finally, we will share insights from our machinists about what it takes to excel in these roles and contribute to the production of superior precision tooling.

Machining Methods: Pros and Cons

Traditional Machining

Advantages:

• Flexibility: Traditional machining is highly adaptable for a wide range of tasks and can be used for both simple and complex geometries without the need for extensive programming.

• Human Expertise: Skilled machinists can make real-time adjustments based on their experience and intuition, which can be beneficial for unique or custom jobs.

• Lower Initial Cost: The initial investment for traditional machining equipment is generally lower than that for CNC machines, making it more common in low-volume or smaller operations.

Challenges:

• Lower Precision: Traditional machining typically relies on manual control, which can lead to variations in precision and consistency, particularly with high-volume orders.

• Slower Production: Manual operations can be time-consuming, reducing overall productivity compared to automated processes.

• Higher Labor Costs: Skilled machinists are required to operate traditional machines, which can equate to higher labor costs over time.

CNC Machining

Advantages:

• High Precision and Consistency: CNC machining offers unparalleled precision and repeatability, which is crucial for manufacturing high-quality grinding tools like electroplated diamond and resin bond grinding wheels.

• Increased Efficiency: Computerized control allows for faster production cycles, reducing lead times and increasing throughput.

• Reduced Labor Costs: Once programmed, CNC machines require less manual intervention, reducing the need for highly skilled labor for routine operations.

Challenges:

• Higher Initial Investment: The cost of CNC machines and the necessary software can be significantly higher than traditional machining equipment.

• Programming Requirements: CNC machining requires specialized programming knowledge, which can be a barrier for some operations.

• Maintenance and Repairs: CNC machines can be more complex to maintain and repair, requiring specialized technicians.

Automated Robotic Machining

Advantages:

• Enhanced Productivity: Automated CNC grinding uses robotic arms that can operate continuously with minimal supervision, significantly increasing production rates and efficiency for producing grinding wheel components.

• Consistency and Quality: Automation ensures that every grinding tool in a series is machined to the exact same specifications, reducing the likelihood of defects and ensuring uniform quality.

• Labor Optimization: Automation frees human workers to focus on more complex and value-added tasks, optimizing labor utilization and reducing repetitive strain injuries.

Challenges:

• High Upfront Costs: Integrating automation involves significant initial investment in both equipment and software, which can be a barrier for smaller companies.

• Technical Complexity: Automation systems require a high level of technical expertise to implement and maintain, which can pose challenges for operations without such capabilities.

• Adaptability: Automated systems can be less flexible than manual operations when it comes to handling custom or unique jobs that require careful planning and programming.

How Machining Fits in CDT's Manufacturing Process

At CDT, machining plays a crucial role in the manufacturing process of our superabrasive products. Whether using resin, metal, vitrified, or hybrid bonds — or our sophisticated electroplating process — precision machining ensures our grinding tools meet the stringent requirements of our customers.

Resin, Metal, Vitrified, and Hybrid Bonds

• Initial Machining: Depending on the tool, CNC machining sometimes occurs before the molding and sintering processes to prepare the core elements.

• Post-Sintering Machining: After molding and sintering, additional CNC machining and manual grinding fine-tune the precision of the finished grinding wheel within customer tolerances.

Plating Process

• Initial Machining: All machining is completed at the beginning, where the desired wheel size and geometry are typically CNC-machined onto a steel core or blank. 

• Minimal Finishing: Once electroplated, minimal finishing is required as the plating process closely mimics the core geometry, allowing for the programming of complex shapes and geometries with minimal additional work.

High Volume Orders

• Initial Machining: With high-volume repeat orders, we utilize automated robotic CNC machining to prepare the core or blank. These systems can run 24/7 to stockpile common wheel sizes.

• Finishing: Every order, large and small, goes through final finishing/machining and several quality checks to ensure that each grinding tool meets our stringent quality standards. This meticulous process guarantees that all products, from vitrified grinding wheels to metal bond diamond tools, adhere to the precise specifications and tolerances required by our customers.

Examples of Machinist Roles at CDT

CNC Operator

The CNC operator at CDT is responsible for programming, setting up, and operating CNC lathes or mills. This role is essential for producing high-precision grinding tools, from electroplated grinding tools to vitrified and resin bond grinding wheels.

• Key Responsibilities:

• Programming CNC machines for various tasks.

• Setting up CNC lathes or mills for production runs.

• Operating CNC machines to produce precision grinding tools.

• Skills and Qualities:

• A passion for learning and problem-solving.

• Logical thinking and attention to detail.

• Willingness to be trained on new technologies.

"To be a good fit as a CNC machinist, you need to enjoy the challenge of looking at a problem and solving it logically. One of the great things here at CDT is if you have limited experience or no experience, we are willing to train." — Ron Fuller, Lead Operator

How to apply >

Manual Lathe Operator

The manual lathe operator at CDT typically works in the metal bond department but sometimes with others as well, handling tasks that require manual precision and expertise. This role can come into play at the beginning, middle, or end of the production process, especially for metal bond diamond tools. 

• Key Responsibilities:

• Operating manual lathes to produce grinding tools.

• Ensuring quality and precision through manual adjustments.

• Overseeing the product quality through all manufacturing stages.

• Skills and Qualities:

• High motivation and a readiness to “get your hands dirty.”

• Reliability and willingness to work overtime on occasion.

• Appreciation for quality, taking pride in your work, and seeing the product evolve.

"What I like about working in the metal bond department is seeing the product go through the process and the steps, and then ending up with the finishing piece. It's satisfying to see that through." — Brian Yates, Supervisor

How to apply >

The CDT Machining Edge

At CDT, we understand the importance of choosing the right machining method to meet the demands of precision grinding tool production. By leveraging traditional machining, CNC machining, and automated CNC grinding, we can offer our customers high-quality diamond grinding wheels, vitrified grinding wheels, electroplated diamond grinding wheels, resin bond grinding wheels, and other superabrasive tools with exceptional precision and efficiency. Each method has its advantages and challenges, and our integrated approach allows us to optimize production based on the specific needs of each project.

As technology continues to evolve, we are committed to adopting the best practices and innovations to deliver the highest standards in the industry. If you are interested in joining our team, apply today at cdtusa.net/careers.

CDT Is Boosting Capacity of Plated Grinding Wheels and Dressing Tools

An electroplated grinding wheel completes machining on CDT’s new PUMA DNT 2600LM CNC Lathe.

At Continental Diamond Tool, we invest in cutting-edge technology, skilled professionals, and continuous improvement. We aim to be the world’s most reliable source for innovative, high-quality, customized precision grinding solutions, offering exceptional performance and long life. The market has responded, and the last several years we have experienced tremendous growth.

To meet growing demand, our manufacturing center in North Wales has recently acquired three new pieces of equipment, made possible in part by the Conwy – UK Shared Prosperity Grant. This strategic investment is set to significantly expand our production capabilities for the manufacture of electroplated grinding wheels and diamond rotary dressers.

The Journey of Investment

In Q3 2023, CDT Ltd. in the United Kingdom embarked on an ambitious venture with the introduction of a new product line at its facility: custom-engineered electroplated cBN and diamond grinding wheels and tools. To support this initiative, we purchased dedicated electroplating tanks, stripping lines, and specialized manufacturing equipment for product testing and prototyping. This setup has been essential in ensuring that these products maintain the same precision and quality customers expect from CDT.

Meanwhile, our Rotary Diamond Dressers line — the specialty of this business center — continues to thrive. Sharing machining equipment between this booming line and the growing orders for electroplated products has become a challenge. Additionally, we are starting to see strain in our inspection capacity with the increased demand for these two technologies.

Strategic Acquisitions for Expanding Production

The introduction of a Puma lathe, OGP SmartScope, and Doosan milling machine addresses these challenges and paves the way for sustainable growth, diversification, and more efficient delivery for our customers.

1. Puma DNT 2600LM CNC Lathe

   The first new equipment delivery took place in May with the arrival of the Puma DNT 2600LM CNC Lathe. This piece of equipment is crucial to meet the increasing demand for electroplated products independently from our rotary diamond dressers. Having a dedicated Puma Lathe for plated products assists in the timely delivery of these high-quality tools to our customers without compromise.

2. OGP SmartScope

   In June we received the OGP SmartScope, a revolutionary 3-axis video measurement system. The SmartScope E7, with its IntelliCentric™ fixed lens optical system, 6-megapixel camera, and 5-position digital zoom, delivers high-resolution images that are essential for precise metrology. This state-of-the-art equipment will expand our inspection capacity to maintain the high standards expected of our precision products.

3. Doosan Milling Machine

   Delivered in early September, the Doosan Milling Machine completes our trio of new equipment purchased with the government grant. This addition further bolsters production, ensuring we have the capacity to meet growing demands and continue our commitment to excellence.

A CNC operator programs CDT’s new PUMA Lathe that was delivered and installed in May.

A CDT quality tech measures a coupon on the new OGP SmartScope that was delivered in June.

A technician operates CDT's Doosan Milling Machine that was delivered in September.

Impact and Future Prospects

With the Puma Lathe, OGP SmartScope, and Doosan Milling Machine now up and running, we are already seeing the benefits in our production processes. The ability to utilize these machines for Plated products independently of our Rotary Diamond Dressers line has optimized our workflow and improved our overall efficiency.

These investments also support a long term strategy for CDT Ltd. They not only address our current production challenges but also set the stage for future growth and diversification at this facility. As we continue to innovate and expand our capabilities, we remain committed to the timely delivery of the high-quality products our clients expect.

Stay tuned for more updates as we continue to enhance our production capabilities and explore new horizons in the industry.

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For more information on the Puma DNT 2600LM CNC Lathe, visit here.

Continental Diamond Tool Ltd., located in Kinmel Bay on the Western Coast of North Wales in the United Kingdom, is dedicated to providing top-tier superabrasive products for precision grinding and dressing.

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At Continental Diamond Tool, we are excited about these investments and look forward to leveraging this equipment to further our mission of excellence in the industry. If you need a solutions provider for your precision grinding applications, please contact our sales team through our website contact form or
call +44 1745-343951 (UK) / 1-800-443-6629 (USA).

Essential Role of Diamond Rotary Dressers in Precision Grinding

Grinding wheels, essential for precision manufacturing and shaping of materials, inevitably wear down with use. This wear occurs due to the abrasive action against hard materials, causing gradual degradation of the wheel’s surface. Over time, the cutting edges of the abrasive particles dull, and the bond holding these particles in place can break down, leading to a loss of material from the wheel. This wear not only reduces grinding efficiency but also affects the accuracy and finish of the ground parts.

"Every grinding wheel, whether it be conventional or superabrasive, requires dressing to maintain its profile and cutting performance. Rotary Diamond Dressers are especially useful for precision applications, when you're trying to achieve micron-level tolerances," explains Ed Pitock, Production Manager for Rotary Diamond Dressers.

The Best tool for Grinding Wheel maintenance

Types of Diamond Rotary Dressers

There are two primary types of diamond rotary dressers, also called diamond rolls:

• Traverse-Style Diamond Rolls: Move across the grinding wheel, providing a comprehensive dressing solution. Often a single traverse-style dresser can be programmed for use with many different profiles.

• Plunge-Style Diamond Rolls: Plunge directly into the grinding wheel, offering uniform dressing of a single precise profile for a specific application.

At Continental Diamond Tool, we custom design both types for our customers to meet the requirements of their processes, machines, and part specifications. This ensures that the desired surface finish and geometry are consistently achieved.

Bond Structures

The bond structure in Diamond Rotary Dressers refers to the material and method used to hold the abrasive diamond particles in place. The bond structure determines the strength, durability, and performance characteristics of the dresser. There are different types of bond structures, each suited for specific applications:

• Infiltrated Bond Structure: Also known as sintered, this structure involves filling the spaces between diamond particles with a powdered metal that is then sintered. It is known for its robustness and longevity, making it suitable for demanding applications.

• Reverse Plated Bond Structure: In this method, diamond particles are electroplated with a layer of nickel. While not as durable as infiltrated bonds, reverse plated bonds allow for more complex geometries and are used for specialized applications.

CVD Inserts

In the context of Diamond Rotary Dressers, CVDs refer to Chemical Vapor Deposition diamonds. These synthetic diamonds are created in a controlled environment, allowing for the production of high-purity and high-quality diamond material. Advantages include:

• Purity: CVD diamonds have fewer impurities compared to natural diamonds, resulting in reliable and predictable performance.

• Consistency: The controlled manufacturing process ensures uniformity and consistency in diamond quality for reliable results.

• Customization: The CVD process allows for the production of diamonds with specific properties that are advantageous to industrial applications. This material can also be cut into specific sizes and shapes for reinforcing of a high wear areas or used as the main lot abrasive in the roll.

CVD diamonds are sometimes added to Diamond Rotary Dressers due to their unique properties, including exceptional hardness, wear resistance, and thermal conductivity. By incorporating CVD diamonds, rotary diamond dressers become a powerhouse in micron-scale precision, superior durability, and enhanced efficiency, making them ideal for highly demanding dressing applications.

Industrial Applications

Diamond Rotary Dressers are utilized across various industries, offering precise solutions for different needs. Key sectors include:

• Automotive: These dressers ensure that automotive components meet stringent tolerance requirements, contributing to the reliability and performance of vehicles.

• Aerospace: The precision of Diamond Rotary Dressers is critical for producing aerospace components capable of withstanding extreme conditions.

• Cutting Tools: These dressers maintain the sharpness and efficiency of cutting tools, enhancing their performance and longevity.

• Bearings: Precision dressing is essential for producing high-quality bearings that meet the rigorous demands of various applications.

By maintaining critical dimensions, enhancing longevity and sharpness, and providing smooth and flawless surfaces, Diamond Rotary Dressers play a vital role in supporting these key industries.

Quality and Customization in Manufacturing

The quality and custom design of Diamond Rotary Dressers are paramount to their effectiveness. "When customers visit our Indiana facility here, they're blown away," notes Troy Giacherio, Product Manager for Rotary Diamond Dressers. "They're going to see the attention to detail, the quality that's taken in every step of the process, and the meticulous customization that we do."

Each product is designed specifically for the customer's process, machine, and part, ensuring a precise fit and optimal performance. This level of customization ensures that the unique needs of each customer are met, providing the ideal solution to their grinding processes.

Customer Support and Technical Expertise

At Continental Diamond Tool, customers also benefit from our extensive support and technical expertise. In 1984, Consort Precision Diamond Company set out to build a reputation as the finest maker of the emerging Diamond Rotary Dresser technology. 

Fast-forward 40 years, under Continental Diamond Tool’s leadership, these advancements have been added to the mix at its 200,000 sq. ft. manufacturing center in the United States. Combining the British ingenuity with CDT’s 50 years of excellence in superabrasive grinding wheels, CDT has solidified its position as a leader in offering this cutting-edge solution for precision manufacturing.

Our Diamond Rotary Dresser departments span two continents and have decades of combined experience. Our team is readily available to assist with any challenges, ensuring that customers receive tailored solutions and guidance. "Here at CDT, our customers can always rely on our experience, our technical expertise, and our customer service," Giacherio emphasizes.

An Essential in Advanced Manufacturing

Diamond Rotary Dressers provide essential solutions for maintaining the efficiency and precision of grinding wheels across multiple industries. With robust bond structures, customization options, and applications in sectors like automotive, aerospace, cutting tools, and bearings, these tools are critical for achieving high-precision outcomes. Continuous investment in advanced technology and quality assurance ensures that Diamond Rotary Dressers from Continental Diamond Tool meet and often exceed customer expectations. By utilizing the latest advancements in superabrasives and precision engineering, these tools address the evolving needs of various industries in their precision manufacturing processes.

Survey Results Are In: CDT Delivers Unparalleled Customer Satisfaction!

At Continental Diamond Tool Corporation, we firmly believe that customer feedback is the lifeblood of our business. It is with great pleasure and enthusiasm that we present the astounding results from our recent customer survey. Your opinions and insights have not only validated our commitment to excellence but have also helped us identify areas where we can continue to improve. Join us as we share the key highlights from the survey and express our heartfelt gratitude to all the incredible customers who participated.

Quality That Exceeds Expectations

Quality 4.8/5

We are thrilled to announce that our CBN and diamond grinding tools have received an impressive average rating of 4.8 out of 5. This outstanding feedback showcases the superior quality and performance that our products consistently deliver. It is a testament to the meticulous craftsmanship and attention to detail that goes into every tool we produce. We are honored that our custom grinding tools have met and exceeded your expectations, and we remain dedicated to maintaining the highest standards of excellence.

Prompt and Reliable Delivery Service

Delivery 4.4/5

Time is of the essence in any project, and we understand the importance of delivering our diamond and cbn grinding products to you in a timely manner. With an average rating of 4.4 out of 5, our prompt and reliable delivery service has earned your appreciation. We recognize that delays can be detrimental to your operations, and we are committed to ensuring that your projects stay on track. Your satisfaction in this aspect of our service fuels our drive to continuously improve and optimize our delivery processes.

Knowledgeable and Responsive Customer Support

Customer Support 4.8/5

A strong and dependable customer support team is vital in providing a seamless experience. We are delighted to report that our customer support has received an impressive average rating of 4.8 out of 5. We take pride in our team's expertise and dedication to addressing your grinding wheel challenges and concerns promptly and effectively. Your positive feedback affirms that we are on the right track in providing the assistance you need, when you need it.

Impeccable Packaging and Presentation

Packaging 4.8/5

First impressions matter, and we understand that the packaging and presentation of our products play a significant role in your overall experience. With an average rating of 4.8 out of 5, our packaging has impressed our customers. We believe that every custom superabrasive grinding tool should arrive in impeccable condition and reflect the value and quality it holds. Your positive feedback motivates us to maintain our commitment to exceptional packaging and presentation standards.

Continental Diamond Tool Corporation as a Whole

Overall 4.6/5

The overall satisfaction rating of Continental Diamond Tool Corporation stands at an impressive average of 4.6 out of 5. This achievement is a testament to the dedication and hard work of our entire team. We are immensely grateful for your recognition and praise, and we are committed to continuously improving our services and products to provide you with an even better experience. Your satisfaction is our ultimate goal, and we will stop at nothing to surpass your expectations.

The results from our recent customer survey have filled us with immense pride and gratitude. The positive feedback and high ratings reflect the trust and satisfaction our customers have in Continental Diamond Tool Corporation. We extend our heartfelt appreciation to all the amazing customers who participated in the survey. Your feedback fuels our commitment to continuous improvement, and we promise to raise the bar even higher to exceed your expectations. Together, we will continue to shine as a leader in the grinding tool industry, delivering exceptional quality, service, and support.

Thank you for being an invaluable part of our journey towards excellence. We look forward to providing for your future superabrasive grinding needs. 

Contact us today for a free quote.

How To Select The Right Bond Type

Congratulations! If you are on this website, you’ve probably come to the conclusion that a superabrasive grinding wheel will be the best solution to your project’s needs. If you are still considering the pros and cons of the different types of grinding products, check out this article that explains the differences between superabrasive and conventional grinding wheels. 

Once you’ve decided you need a superabrasive solution for your grinding application, what’s the next step? 

SELECTING YOUR BOND TYPE

The bond acts as the glue that keeps the abrasive grains in your grinding wheel connected. The bond's strength, also known as its hardness, determines how well the wheel can handle different materials. 

Harder bonds are typically recommended for softer materials and vice versa. There is also the option to create custom hybrid bonds that are specially formulated to possess unique characteristics that will better support your more specific needs.

A grinding wheel expert can help you narrow down your selection, as there are many different bond types.

Let’s go over the common ones:

• Resin Bond

• Metal Bond

• Vitrified Bond

• Electroplated Bond

• Hybrid Bond

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RESIN BOND

Resin bonds are the most widely used bond type in superabrasive grinding wheels. Simply put, they are grinding wheels held together with a plastic bond.  They are made from synthetic resins, such as phenolic or epoxy, which is used to hold the abrasive in place. 

Mostly, these types of grinding wheels are formulated and blended as powders which are then cast and hot pressed in steel molds of the desired size and shape of grinding wheel desired.  The specific properties of the bond are determined by the specific resin and additives to get the desired mechanical and grinding properties.

Because of Resin Bond’s resilience and toughness, these grinding wheels tend to be:

• Easy to use

• Versatile across a broad range of materials & applications

• Relatively inexpensive when compared with other superabrasive grinding wheels

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METAL BOND

Metal bonds are, as the name suggests, made from metals – such as bronze and iron. Like Resin Bond products, Metal Bond grinding wheels are blended as powders and hot pressed in high temperature alloy or graphite molds as the processing temperature is much higher than resin.

Metal bond is the hardest of the bond types. Because of this, most Metal Bond grinding wheels are made with diamond, the hardest superabrasive, and are used on especially hard materials such as glass, ceramics, and carbides. Between the inherent hardness of the bond and the hardness of the materials being ground, these wheels generate the highest grinding forces and usually require special dressing or conditioning steps during use.  

Benefits of Metal Bond grinding wheels include:

• Resistance to wear

• Longest wheel life

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VITRIFIED BOND

Vitrified (or more appropriately known as “glass” or “ceramic”) bonds are different from resin and metal bonds in that they have both a mechanical bond like the others, but also a chemical bond between the abrasive (either dIamond or CBN) and the bond itself.  Most commonly, these bonds are engineered with porosity and are “cold pressed” and sintered as opposed to hot pressed.

While the actual glass/ceramic bond is technically harder than metal bonds, the porosity levels make the function better in grinding as the porosity efficiently removes grinding debris (swarf) and brings coolant into the point of grinding. Because of the porosity of these grinding wheels, they are also more readily able to be dressed and formed into specific desired geometries.

Because Vitrified bonded grinding wheels have lower grinding forces and the ability to be readily dressed with rotary dressers, this type of bond is ideal for high volume production grinding applications of hard materials that can most benefit from the:

• Lower grinding forces

• Faster grinding cycles 

• Lower scrap rates

In the case of CDT’s VIPER Vitrified Bond grinding wheels, we have enhanced the bond strength over traditional Vitrified Bonds, coupled with a porous vitrified structure, to more perfectly grind some of industry’s hardest materials like silicon carbide, aluminum oxide, glass, carbide, and others. Our VIPER Bond system provides enhanced dressability, lower grinding forces, and shorter grinding cycles over traditional Vitrified Bond systems.

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ELECTROPLATED BOND

An electroplated bond is a metallic bond (typically nickel for superabrasive grinding wheels) in which a single layer of abrasive is adhered or bonded onto a metallic core through a deposition process.  Like all electroplating processes, metallic material is pulled from solution and deposited onto the substrate, encapsulating the abrasive onto the substrate in the same form as the substrate.

Like the other bond types, both diamond and CBN superabrasives are used depending on the application.  Because electroplating is a liquid process, complex shapes and geometries are more readily achieved and generally don’t require dressing when in use.

Another benefit to using electroplated grinding wheels (also referred to as just ‘plated grinding wheels’) is that they are single layer and used wheels are able to “stripped” or reverse plating process and the substrate/core can be reconditioned and used again resulting in potential savings of as much as 40% over new plated products.

To recap, Plated grinding wheels:

• Generally don’t require dressing

• Can be designed in complex shapes and geometries

• Can be reconditioned and used again for cost savings over the life of the wheel

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HYBRID BOND

A hybrid bond is a combination of two or more different types of bonds and/or processing methods to create a “Hybrid” that encompasses enhanced properties to achieve better performance in grinding for a specific application.

For example, resin and metal bonds have successfully been combined into a single wheel in our EVO Hybrid Bond grinding wheels designed for the cutting tool industry. In this hybrid resin/metal bond wheel, the hard metal bond is softened to make it more user friendly while maintaining long life.  

New hybrid bonds and technologies continue to be developed to bring enhanced grinding performance to specific production grinding processes.

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NEXT STEPS

To dig deeper into why different types of materials require different grinding solutions, check out our previous blog Why Different Materials Need Different Grinding Wheels.

Grinding is a complex process that requires a total “systems” approach. Your grinding solution needs to encompass; the grinder/machine, dressing/truing requirements, material, coolant, and the grinding wheel. 

If you’re ready to move forward with a quote or investigate the advantages of a certain bond type for your specific application, contact us to speak with our team of expert engineers that will help answer your questions and get you started.

Top 10 Super Characteristics of Superabrasives

Superabrasive grinding products get their ‘super’ characteristics from the extremely hard substances used to make them. Unlike conventional grinding wheels that are created using blends of less durable abrasive grains, superabrasives use industry’s the hardest known substances to achieve their abrasive properties.

Diamond has the most extreme Knoop hardness rating around 7,000, with synthetic or manmade diamonds having a more consistent hardness than its naturally occurring counterpart. The other popular superabrasive material, cubic boron nitride (CBN), is an extremely hard synthetic grain with a Knoop rating of 4,700. Conventional grains typically range from 2,100 to 2,500.

Upfront cost for these superabrasive grinding products is very high when compared to conventional abrasives, so what makes them so valuable to many industries? The secret is in this product’s return on investment.

Here are the top 10 reasons you should consider a superabrasive solution for your precision grinding or finishing process.

10. Decreased Cost Per Part

9. Decreased Cost in Swarf Management

8. Increased Production Parts Per Dress

7. Multiple Profile Grinds Without Dress

6. Less Residual Stress or Damage to the Part

5. Increased Throughput

4. Lower Grinding Pressure

3. Higher Removal Rates

2. Improved Surface Finish

…and the number one reason superabrasive products are a ‘super’ solution to your grinding and finishing needs:

1. Lower Overall Tooling Costs

When companies add up the superior precision, efficiency, quality, and durability that comes with a superabrasive grinding wheels, superabrasive grinding wheels and tools quickly justify their upfront cost.

If you are interested in a free quote, contact our customer service team to discuss how a superabrasive solution can be used to improve your company’s bottom line.

Superabrasive Manufacturing: The Industries We Serve

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For industries that need to shape some of the world’s hardest substances like tungsten carbide, ceramics, and superalloys, only an extremely tough tool can do the job. Applications like these require grinding wheels and tools made with the most durable materials for cutting: natural or man-made diamond and cubic boron nitride (CBN).

Ironically, delicate substances like silicone also require the special characteristics that only these superabrasive materials can provide. With a wide variety of forms, grades, and bonds, CDT is proud to supply high-precision custom superabrasive grinding and finishing solutions for a variety of commercial, industrial, and military applications.

Here’s a rundown of industries that are known to benefit from the toughness and precision of custom CBN and diamond grinding solutions:

AEROSPACE & MILITARY

Top aircraft turbine manufacturers in the United States and around the world require precision plated form wheels and form mandrels in the manufacturing of turbine blades and other various engine parts. CBN grinding technology can be used for both the manufacturing of aircraft engine components and land-based turbine engine components. Efficient manufacturing needs shorter production runs and longer cycle times. Plated CBN wheels are the preferred choice for high precision form grinding applications of this nature.

CDT engineers are experienced with the demands of military and commercial aerospace applications, particularly in regard to turbine engine tooling and grinding solutions. We've even manufactured tooling for interplanetary use. As a leader in the manufacturing of diamond grinding tools for both air frame and aerostructure components, CDT is well-equipped to tackle this industry’s most challenging manufacturing needs.

For aerospace and military applications, superabrasive solutions are useful in working with:

• Composites

• Composite Material

• Honeycomb Composites

• Graphite & Kevlar

• Reinforced Plastics

• Titanium

AUTOMOTIVE

Over the years, CDT has proven to be a reliable partner to the automotive industry as a supplier of grinding tools for machining engine, chassis, and transmission components. We provide the continuous innovation, wide range of superabrasive capabilities, high quality standards, and delivery reliability that the automotive industry needs to stay competitive in an ever changing world.

The automotive industry uses superabrasive grinding products in the manufacture of many components such as:

• Engines

• Brakes

• Steering, Suspension Systems

• Parts

• Rubber, Tires

• Windshield Glass, Mirrors

• Body Parts

CERAMICS

With extreme hardness that in some cases surpasses that of metals, the properties of ceramics offer unique opportunities and challenges for grinding in this industry. From circuit board parts, kitchenware, solar panels, pipes, and tubes to advanced technical ceramics and refractories, the ceramics industry manufactures a vast range of products that require the special characteristics of superabrasive wheels and tools. With our reputation for high precision diamond grinding wheels that work longer, cut faster, and are more durable, leaders in the ceramics industry regularly turn to CDT engineers to help them achieve their most demanding grinding and finishing requirements.

The ceramics industry uses superabrasive tools for the grinding and finishing of:

• Glass

• Brick, Refactories

• Ceramics

• Carbon, Graphite

• Lavatory

• Alumina

COMPOSITES, FIBERGLASS & PLASTICS

CDT has an electroplated process that is specially formulated for composites and provides outstanding cutting speed and efficiency. Our engineering team specializes in helping our customers create successful, cost effective solutions for their manufacturing needs. This applies to all types of composites, from FRP to fiberglass to Kevlar® aramid fiber. CDT's electroplated wheels have seen great success in all areas where composites are used, including: automotive, aerospace, sporting equipment (golf clubs, archery, bicycles, etc), wind energy, and military applications.

Many industries turn to superabrasive solutions when manufacturing requires these composite and fiber-reinforced plastic materials:

• FRP Corrosive Resistant Material

• Marine Fiberglass

• Cultured Marble Types

• Thermoset Resin Materials

• Fiberglass Reinforced Plastics (FRP)

• Composites

CUTTING TOOLS

For those companies involved in the manufacturing or resharpening of cutting tools, superabrasives have the strength and durability that such metal manipulation requires. Superabrasive tools that are custom designed to the required specs can reduce the cost per part, meet high-precision quality standards, and provide superior value.

Our engineering department has much experience achieving tighter tolerances and better performance, even with this industry’s extremely tough materials. A well designed custom grinding wheel can take a company to the next level, increasing efficiency while saving resources and time.

For the cutting tools industry, superabrasive tools are superior at grinding and finishing metals such as:

• Carbide

• High Speed Steel

FOOD PROCESSING, PAPER & CARDBOARD

Manufacturers of cutlery and hand tools turn to CDT superabrasives for many grinding applications. Cool cutting, fast stock removal, excellent finish, superior wheel life, and an attractive return-on-investment are prerequisites for success in the demanding grinding required in food processing and paper/cardboard.

Industries involving food processing, paper, and cardboard use superabrasive grinding products in applications such as:

• Blade & Knife Sharpening

• GEM

• Precious Stone

• Semi-Precious Stone

• Corrugated & Flat Cutters

GEARS

CDT is a partner to the gear industry. Our areas of expertise include grinding wheels for virtually every operation needed in the production of gears and gear components. More broadly, our custom engineering department helps companies develop products that will maintain and improve production efficiencies on a continuous basis for whatever the customer’s need.

The gear industry uses superabrasive tools in the manufacture of:

• Gear, Thread

• Gear Guide, Bed

MEDICAL/DENTAL

From bone sawing to intravascular applications, CDT is regularly commissioned to engineer high precision tools for medical use. Our engineers understand the thorough testing and quality processes associated with medical device manufacturing . Our products are designed with exacting standards to achieve the tight tolerance demanded by this industry.

Medical and dental industry uses for superabrasive tooling include:

• Prosthesis

• Dental Instruments

• Surgical Equipment

OIL & GAS

When the oil and gas industry has a job that calls for high precision grinding of carbide and PCD drill bits, wear parts, and gage blocks for oil and gas drill manufacturing, efficiency and effectiveness are extremely important. ID grinding is an exacting process that requires unparalleled precision for reliable, repeatable results. And, this industry’s CNC OD Grinders have their own unique challenges in these most difficult center-type grinding projects.

CDT has developed superabrasive advanced bond technology perfectly suited to all these needs of the oil industry. We also custom engineer each tool for longer tool life and a high stock removal, making it the best value in the industry.

The oil and gas industry turns to superabrasive tools for:

• PCD/Carbide Grinding

• I.D. / O.D. Grinding

POWER GENERATION

CDT has the capability to produce thousands of precision-built superabrasive products of high quality, performance, and repeatability for virtually every conceivable manufacturing area involved in power generation. The diversity in this industry calls for Vitrified, Resin Bond, Plated, and Metal Bond Diamond and CBN products to get the job done.

For the power generation industry, superabrasive tools are most commonly used in the manufacture of:

• Wind Turbine

• Gas & Steam Turbine

• Marine Turbine

• Blades

WOOD/SAW

CDT is experienced at supplying custom superabrasive products for the lumber and wood products industry. We provide grinding solutions for OEM manufacturers, filing rooms and service shops for their processes of manufacturing and maintaining band saws, circular saws, chippers, planers, and paper knives. All in all, our grinding wheels are designed to help our customers maintain and improve production efficiencies on a continuous basis.

Industry leaders in lumber and wood products use superabrasive tools for applications such as:

• Carbide Tip Saw Blades

• Band Saws

• Knife Sharpening

OTHER MARKETS

Continental Diamond Tool has been providing technically superior precision tooling solutions to numerous other distinct industries since 1973. Over the years, we have witnessed more and more companies realize the productivity increases possible with the use of custom superabrasive products. With more parts processed per wheel and fewer wheel changes, many see how investing in this level of quality and durability pays off.

Along with those highlighted above, below are additional industries who have turned to CDT for superabrasive grinding solutions:

ELECTRONICS

• Ferrites, Magnetics

• Substrate (Ceramics, Glass, IC)

• Quartz Crystal

• Semiconductors

• Printed Circuit Boards

OPTIC & PRECISION

• Lens, Prism

• Measuring Instruments

STONE

• Lapidary Tools

• Refractory Brick

• Peek Materials

• Granite

TOOL & DIE

• Cemented Carbide Tool & Die

• Special Steel Tool

• Molding Die

• Bearing

• Pneumatic, Hydraulic, Valve

• Jig

WIRE & CABLE

• Precision Die

How much does a Custom Superabrasive Grinding Wheel Cost?

A Look at the Bigger Picture >

As a custom-made product, the cost of a superabrasive grinding wheel can vary greatly from one design and application to the next. People may shy away from custom products because they think one of two things: it’s going to cost a lot more or it’s going to take a long time to complete. While that may be partially true on the surface, that’s not the whole picture.

In this article, we’re going to take a look at some of the factors that will help you assess the “total cost” of custom grinding products, which includes both what the product is and the value it provides over time. When taking everything into account, our clients often find that the custom grinding product that appeared to be too expensive actually has a return on investment that quickly pays for itself.

Here are 4 advantages to purchasing custom superabrasive grinding wheels from Continental Diamond Tool so you can weigh their value long-term:

1) Custom Grinding Wheel means a better fit.

With the right custom grinding wheel, customers have reported upwards of a 70% improvement in efficiency from conventional wheels. Our engineers work with you to reduce cycle times, maximize removal rates, minimize maintenance requirements, decrease material damage, and improve productivity wherever possible.

During the design phase, we can run simulations from our facility or travel to yours. We frequently visit customers to learn their machinery, materials, and processes so we can design a better grinding wheel that works for what they need. Some of our product options can be incorporated into lights out production which can be an even great boost to your company’s overall efficiency.

With each tool custom designed for your unique application, you get productivity out of your grinding wheel that you’ve likely never seen before. When you factor in these benefits, ROI skyrockets.

2) Custom Grinding Wheel means quality work.

Conventional wheels off the assembly line will never match the quality of custom grinding wheels from an experienced manufacturer. Custom grinding wheel manufacturers generally do not cut corners like you see with commodity products. At CDT, we use the best quality materials because it’s in our best interest to maintain longterm relationships with customers and the superiority of our products.

Experience can also be a factor with quality. Even within the industry of custom superabrasives, inexperienced engineers can cost you in development time, troubleshooting hassles, and subpar products. At CDT, we have almost 50 years of experience in old and new grinding technologies. And we’re always updating our quality control systems with state-of-the-art precision testing equipment to make sure you are getting the most efficiency from your custom grinding wheel investment.

3) Custom Grinding Wheel means the product will last.

Superabrasive grinding wheels are made from natural diamond, manmade diamond, and CBN —some of the strongest materials known to man. Conventional abrasives are made from materials like aluminum oxide and silicon carbide — much softer materials that break down more quickly. Depending on your application, a more durable product that you don’t have to replace as often may actually be a better investment.

Additionally, we have options with some of our superabrasive products where we can recommend dressing tools and even refinishing or replating services that can make your grinding wheels last even longer.

4) Custom Grinding Wheel means a great customer experience.

You may be wondering how great service actually saves you money. First, the customer service team at Continental Diamond Tool provides free quotes, product selection and design assistance. You don’t have to research and guess what you need. A specialist will provide product recommendations and a competitive quote for you for free.

Second, a company like CDT whom you have a personal relationship with will do everything they can to help. For example, we know that waiting on a grinding wheel order can be painful for your company’s productivity and bottom line. Delays may throw off your production calendar and anger customers. That is why we’ve taken measures — like stocking an extensive inventory of raw materials — so we can deliver your order faster than others in the industry. Additionally, once your product has been developed, a reorder can be produced and shipped much faster.

Third, service doesn’t stop at the sale. While some big name custom superabrasive and conventional wheel manufacturers have cut corners in service for better bottom lines, CDT has remained true to our founding principles. Does your grinding wheel supplier train your team on installation and maintenance? Will they come to your facility to review your machinery and processes to make sure your grinding wheel is optimized for peak performance? Do they notify you when new technology becomes available that could make your processes even more efficient? At CDT, our personal sales team and tech support are here to help you overcome the obstacles to increased productivity and success.

Learn more about superabrasives and how they differ from conventional grinding wheels in this video:

To get started with custom superabrasive grinding wheels from CDT, contact us for a free quote.

Pushing the Bounds in Grinding Technology

In today’s competitive advanced manufacturing space, industry leaders know that staying a step ahead means continuously pushing the bounds of what’s possible. Materials are harder, tolerances are tighter, and cycle times are shorter than ever before. In this environment, precision is essential. Well designed custom tooling can provide the edge you need to make your processes that much better.

When Ray Viggiano set up shop in 1973, his philosophy was simple:

If a customer needs it,

CDT makes it happen.

Over the years, a lot has changed, but this philosophy has stayed the same. In this video, you can see Continental Diamond Tool's state-of-the-art facility. Learn how we've grown into a leading manufacturer of superabrasive grinding wheels and diamond dressers that set new standards in the industry. Watch how we have assembled the technology, materials, and expertise to tackle the toughest jobs out there with precision and excellence. And hear about our can-do culture that has been the foundation for our company's success.

At CDT, we are committed to producing grinding wheels with the highest quality, performance, and accuracy. If you need it, CDT will make it happen. To get started, call us or request a quote.

Plated Diamond Rotary Dresser Operations Expanding for Increasing Demand

Diamond Rotary Dressers are widely recognized as the most efficient, cost effective means of dressing and truing grinding wheels to the correct tolerance, form, and condition. As industry is experiencing an increasing demand for high-accuracy, high-speed production, the need for reverse plated dressers is also increasing.

Always striving to stay ahead of the curve in technology, CDT-subsidiary Consort Precision Diamond is excited to announce that our newly upgraded plating lab is up and running.

"This plating lab expansion more than doubles our capacity to produce the high quality tight tolerance reverse plated rotary dressers used by some of the most prestigious companies in the world," says Troy Giacherio, Product Manager at Consort Precision Diamond. Stephen Noakes, Production Manager, lead the team who worked on the plating lab upgrade.

Choosing the Best Diamond Rotary Dresser
There are two types of production methods for diamond rotary dressers, sintering and plating. Consort Precision Diamond specializes in the manufacture of both types.

Sintered diamond rotary dressers are suitable for large quantities of high precision machining and many types of high hardness grinding wheels.

Reverse plated diamond rotary dressers are best suited for applications where high accuracy of profile detail and a correspondingly high quality surface finish on the component are required.

Our Commitment to Excellence
If your application calls for a Diamond Rotary Dresser, Consort Precision Diamond is committed to providing you the best tool for the job. Our service techs are skilled at helping you find the correct specifications optimized for your application. Contact us today >

Consort Precision Diamond is a subsidiary of custom superabrasive grinding wheel manufacturer Continental Diamond Tool Corporation. Learn more about Consort’s products at www.consortprecision.co.uk.

Custom Rotary Diamond Dressers in as little as 4 weeks: How do we do it?

Since 1984, Consort Precision Diamond has supplied diamond wheel dressing products to a broad range of industries including aerospace, aircraft, automotive, blade and knife, power generation, medical, cutting tools, tool & die, saw, gear, and bearing and many other applications. What all these grinding operations have in common is that they typically require some form of wheel dressing to re-establish the wheel profile and/or recondition the wheel face.

About Wheel Dressing or Conditioning

Wheel conditioning involves the sharpening and opening of the wheel face, while also removing dull abrasives, excessive bond, and workpiece material (loading). A sharp and open wheel face will allow maximum possible material-removal rates and reduced thermal stress on the workpiece.

Consort’s rotary dressers provide the ideal profile for your desired wheel topography, with superior materials and manufacturing technology. Because your dresser is custom manufactured, demanding and complex configurations are possible.

Diamond Roll Delivery in as Little as 4 Weeks

The question then turns to delivery and lead times. In business, time is money. Industry-standard lead times for custom rotary diamond dressers can take 8 weeks or more. That’s a long time to wait for a critical part in your manufacturing process. Consort has made a reputation for fast delivery with a standard lead time of 6-8 weeks.

Need a tool in a hurry? Customers can request “Expedited Service” for custom diamond roll delivery in as little as 4 weeks. With manufacturing, delaying maintenance can really add to your costs in the long run. When a job is expedited, we work with our customers to get them their tooling as soon as possible.

We pride ourselves on prompt service and communication. At any time, you can reach out to your Consort account representative to begin an order or find out its status. If you do not have an account rep, please reach out to our customer service through our website online form or call 800-443-6629.

Lead times should not be a hurdle in the proper maintenance of your grinding equipment. If you are looking for a better, faster diamond roll supplier, let our service techs help you get the process started.

6 Common Grinding Problems and How to Solve Them

Most grinding problems affect one of two categories: either appearance of the workpiece or productivity and return on investment. After verifying that the grinding machine isn’t at fault, there is one likely culprit causing your grinding problems: your grinding wheel.

Poor surface finish, chatter, and burning all affect the appearance of your product. Productivity issues like short wheel life, slow or inefficient cutting, or the wheel not cutting at all are also costly problems to have.

Let’s take these one at a time to see how a fix to your grinding wheel can solve some of your most challenging grinding issues.

1) Poor surface finish

Why your grinding wheel may be at fault:

In the appearance category, poor finish is a common complaint when your grinding wheel isn’t optimized. Grinding is a multi-point cutting process, but broken down to the microscopic level, it has similarities to a single point operation like turning. Viewed this way, it’s easy to see how surface finish is affected by the same factors: the more material removed by each grinding point, the bigger the individual chips and the rougher the surface. 

Solutions:

• Select a grinding wheel with a finer grit size

• Reduce the relative speed between the wheel and workpiece

Other possibilities:

• If grinding wet, the coolant may not be efficiently removing chips from the workpiece or wheel interface.

• It's also possible that the wheel is being dressed excessively, creating grinding points that are standing too proud of the wheel surface.

2) Chatter

Why your grinding wheel may be at fault:

Recognizable by a distinct, often audible, pattern on the workpiece, chatter has many causes. Wheel-induced chatter occurs when an out-of-true grinding wheel acts as an excitation source.

Solutions:

• In this case the wheel should be trued carefully.

• Also check that it isn’t slipping on its mount.

Other possibilities:

• If the problem is tracked down to a vibration in the machine — possibly some kind of resonance — the solution is to vary the grinding speed. Try going 10% faster or slower to remove the forcing excitation.

• A detailed discussion of chatter is available at the Abrasive Engineering Society website.

3) Burning

Why your grinding wheel may be at fault:

Machinists use the term “burning” to describe thermal damage. It can show up as cosmetic discoloration, changes in workpiece hardness, and possibly distortion-inducing internal tensile stresses. Burning can occur if the wheel is glazed or loaded, causing more rubbing and friction. This often occurs if the machinist is trying to push the wheel through the workpiece too quickly or using a wheel that’s too durable. 

Solutions:

• Dress the wheel with the correct dressing tool

• Reduce the feed rate or the relative velocity between wheel and workpiece.

Other possibilities:

• Burning is far more common when grinding dry, although can still be experienced in wet grinding if there isn't enough coolant flow to carry away the heat.

• See “Burn Awareness”, originally published in Cutting Tool Engineering, December 2000, for more information.

4) Wheel life too short

Why your grinding wheel may be at fault:

This costly issue can be caused by a wheel that's either too hard or too soft for the workpiece. When this is the case, the grinding wheel loads up or wears away too quickly.

Solutions:

• Try a grinding wheel manufactured with a different material that is better suited for your grinding operation.

Other possibilities:

• Insufficient coolant

• Dressing your grinding wheel too frequently

• Wheel speed too low

5) Wheel cutting slowly

Why your grinding wheel may be at fault:

This productivity issue is usually caused by feeds and/or wheel speeds that are too low. If you are using the wrong type of grinding wheel, you may be forced to cut slowly to avoid burning, but ultimately that’s not efficient for your process.

Solution:

The solution is to find a wheel that can grind as fast as possible without burning. A grinding wheel specialists can suggest alternatives that will increase speed for your specific operation.

6) Wheel not cutting at all

Why your grinding wheel may be at fault:

Most likely, this happen when the grinding wheel is glazed by truing.

Solution:

The solution is to dress the wheel lightly until the grit opens up. For dressing advice, consult with a grinding specialist.

OUR BEST ADVICE: THINK LOGICALLY

Most grinding problems can be solved by tracing the fault back to basic principles. With all grinding applications, imagine your material being removed by individual cutting points. Thinking from this perspective, a solution usually emerges.

Also, use your resources. The grinding experts at CDT are happy to discuss your cutting and grinding issues and offer solutions that will set your manufacturing operations on track to success.