Who Uses Vitrified Grinding Wheels and Why?
At CDT, our Vitrified products generally serve two distinctly different markets, Vitrified CBN and Vitrified Diamond. As the two hardest known materials, CBN and Diamond are referred to as superabrasives and both are excellent thermal conductors.
These abrasive properties when combined with our porous vitrified structures allow for:
longer wheel life
shorter grinding cycle times
automated grinding production capabilities with wheels dressed right on the grinder
CBN vs. Diamond
Vitrified CBN products are ideal for steel and ferrous alloy grinding applications in automotive, aerospace, medical, production tooling, etc. They are excellent thermal conductors and do not react with ferrous materials during the grinding process like diamond does.
We regularly customize Vitrified Diamond products for grinding ceramic and carbide materials used in industries such as glass, ceramics, computer chip manufacturing, thermal spray coatings, and more. Diamond is the hardest known material with the best thermal conductivity making it the best abrasive where there is no chemical reaction.
We are uniquely qualified in both types of Vitrified products because of our full range of manufacturing capabilities and technical application support. Because we handle the vitrification process entirely onsite, we have full control of the manufacturing process and a standard lead time of about 3-4 weeks — about half as long as the industry standard.
The Vitrification Process
At CDT, we use a cold press and sintered process to press near net shape with highly and tightly controlled sintering. This fuses the Vitrified/Ceramic bond together with the Diamond or CBN into a porous structure. CDT's vitrification process is unique in how our engineers have developed a series of custom bonds, formulations, and structures to offer our customers superior grinding performance when compared with off-the-shelf or other competing products.
Combining either of these two abrasives with a porous vitrified bond offers a very strong and stiff system in which the porosity brings coolant into the grinding zone. This innovation removes heat and grinding debris (or "swarf") to extend the wheel life and improve performance. CDT's Vitrified Diamond and CBN wheels generally provide 100 to 300 times the grinding wheel life and maximize the amount of material being ground compared with conventional grinding wheels.
Reducing Cycle Times
"Cycle Time" is the term used to describe the grinding process. Our porous vitrified grinding wheels offer greater efficiency through more effective coolant delivery and swarf removal. This also extends the life of the grinding wheel requiring less downtime for wheel dressing.
When compared with conventional wheels, we see an 80-90% cycle time reduction with our custom vitrified wheels. Even compared with other superabrasives such as Resin and Metal Bond Diamond and CBN wheels, we see 40-75% reductions in cycle times with vitrified wheels.
From military/defense and energy sectors to mold & die markets and everything in between, we have found unique opportunities for more efficient grinding using custom Vitrified products in many industries. Our engineers would be happy to discuss the parameters for your process and provide a free analysis and quote for a custom grinding solution that works best for your application. Contact us today >