Tips To Solving Wheel-Related Grinding Problems

Grinding problems show up in two ways: in the appearance of the workpiece and as cost or productivity issues. After verifying that the grinding machine isn’t at fault, attention should turn to the grinding wheel.

Appearance problems divide into poor surface finish, chatter, and burning. Cost and productivity issues are short wheel life, slow cutting, and the wheel not cutting.

APPEARANCE ISSUES

 Poor finish

Grinding is a multi-point cutting process, but down at the microscopic level it’s little different 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, bigger the individual chips and the rougher the surface. 

The solutions are:

• Select a finer grit size

• Reduce the relative speed of wheel and workpiece

If grinding wet, it might also be that the coolant is not removing chips from the workpiece/wheel interface. It's also possible that the wheel is being dressed excessively, creating grinding points standing too proud of the wheel surface.

Chatter

Recognizable by a distinct pattern on the workpiece, and often audible, chatter has many causes. If initiated by 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.

Wheel-induced chatter occurs when an out-of-true grinding wheel acts as an excitation source. In this case the wheel should be trued carefully. Also check it isn’t slipping on its mount. A detailed discussion of chatter is available at the Abrasive Engineering Society website.

Burning

Machinists use this term to mean thermal damage. It can range from cosmetic discoloration to changes in workpiece hardness and possibly the creation of distortion-inducing internal tensile stresses. 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. “Burn Awareness”, originally published in Cutting Tool Engineering, December 2000, provides more information.

Burning can occur if the wheel is glazed or loaded, so there is more rubbing and hence more friction, by trying to push the wheel through the workpiece too quickly, or by using a wheel that’s too durable. 

Solutions are:

• Dress the wheel with a dressing stick

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

COST AND PRODUCTIVITY ISSUES

Wheel life too short

This can be caused by:

• Insufficient coolant

• Dressing too often

• A wheel that's either too hard or too soft for the workpiece (so it loads up or wears away too quickly)

• Wheel speed too low

Slow cutting

Usually caused by feeds and/or wheel speeds that are too low, the solution is to grind as fast as possible without burning.

Wheel not cutting

This happens when the wheel is glazed by truing. The solution is to dress the wheel lightly until the grit opens up.

THINK LOGICALLY

Most grinding problems can be solved by relating the fault back to basic principles. Picture material being removed by individual cutting points and a solution usually emerges.

How to Keep your Grinding Wheels Performing Every Time

Grinding wheels are a very important tool in many factory and shop situations. They can be used for any number of projects; because of this, they tend to become something that are taken for granted. You expect that when you go to the shop that the grinding wheels will work as intended.

However, there are a number of issues that can occur that prevent the wheels from grinding as they should. While some of these problems are big and require a replacement wheel, others are reparable. One of the most common problems is a wheel that is not providing as heavy of a grind as it should.

Commonly, new wheels may not have the same grinding power as wheels that have been “broken in” and used for some time. As such, it is important to understand the concept of dressing grinding wheels.

To get the best cutting performance from your grinding wheel it is important that the wheel have a sharp abrasive grain with cutting points that are well exposed and able to connect with the piece with which you are working. 

The ultra-hard abrasive crystals often used in grinding wheels will remain sharp simply through the process of grinding itself. Essentially, the wheels will slowly expose further crystals and you will not need to continuously dress the wheel. This is one of the biggest benefits of these superabrasive grinding wheels.

However, one problem is when you are working with new wheels. Usually these wheels have a smoother grinding surface. This occurs because the crystals and the surrounding bond are still flush to the edge of the cutting surface. If you try to operate a wheel without first dressing it, you will find performance is lacking. This is called “loading.” A wheel that is loaded will have poor cutting performance and may even cause some burning to your work piece.

This is where dressers come in. Diamond dressing sticks or rotary diamond dressers (also known as diamond rolls) are supplementary tools that keep your wheel operating at peak performance.

Dressing your superabrasive grinding wheel enhances grain exposure and brushes away some of the bond so that the wheel will work as it should. However, it is important that you choose the right type of dressing for your wheel to get the performance you desire. Some of the qualities you should consider with your grinding wheel dressing include:

• Hand held aluminum oxide or silicon carbide stick

• Soft (G, H hardness)

• Fine grit (200-400 mesh)

Another strategy is to lower the RPM of the spindle, at least temporarily. This will open the wheel quicker and expose the abrasive surface for a more open surface. Then, you can increase the RPM in the future when the abrasive surface has been properly dressed and exposed.

While dressing your wheel is often something that only occurs when the wheel is new, it is possible to experience burning and poor cutting even on an older wheel. If this happens, you can simply use the same stick and technique to re-expose the surface and reopen the wheel.

As you can see, there is a lot to think about when you are first setting up your grinding wheel or if you are working with a wheel that does not seem to offer the best performance. It is possible to get the performance you desire it just takes a little work and effort up front!

Hardness Matters. Best Materials for Drilling, Cutting and Grinding

A natural diamond is the hardest material on the Knoop Hardness Scale, as is well known. It is considered a superabrasive, and has a long list of things it is regularly used to drill or otherwise shape. Glass, plastic, cemented carbide, ceramics, fiberglass, electronic components and materials, and titanium alloys are just a sampling of the things a diamond can cut. This is true whether the diamond is natural, manmade, or polysrystalline, as all three of these diamond types top the Knoop Hardness Scale. This means that even non-natural diamonds are harder than anything else except a natural one.

Right after the diamonds comes the Cubic Boron Nitride (CBN). This measures at nearly 5,000 on the Knoop Hardness Scale (compared to the 10,000 for a natural diamond, for comparison). At only half the hardness of a natural diamond, CBN is the only other material besides synthetic diamonds that is hard enough to be considered a superabrasive.

Everything else on the Knoop Hardness Scale is less hard than natural and synthetic diamonds and CBN. This means these things can cut through nearly everything else. The vast difference between the hardness of a natural diamond and the hardness of CBN shows just how relatively soft everything else on earth is in comparison to a natural diamond. If it wasn't for CBN, there would be no other super abrasive at all.

Superabrasives are split into two categories: CBN for use with ferrous material, and diamond for almost all other materials.   Conventional Abrasive grinding wheels are also split into the same two categories.  Silicon Carbide is known to chemically interact with ferrous materials making it less than ideal for such materials.  Aluminum Oxide, despite being somewhat softer than Silicon Carbide, does not have chemical reactivity with Ferrous materials, and is therefore a better choice for these materials.

So the question becomes which is the better choice;  conventional abrasive or superabrasive grinding products for your application? In general, superabrasive grinding wheels can provide 100-300 times the grinding wheel life when compared with conventional abrasives due to their higher hardness values, while only costing 10-30 times the wheel price.  However, significant other variables have to be considered when determining which type of grinding wheel is best for your application.  These include the machine/grinder, dressing of the grinding wheels, work piece material properties, coolant type and delivery, etc…..

Please contact one our experienced engineers to help evaluate your grinding process today to see if superabrasives are the ideal solution for your grinding application. 

CDT Now Offering Same Day Shipping on Select High Performance Grinding Wheels for the Cutting Tool Industry

Last year Continental Diamond Tool Corporation introduced its Resin Hybrid Bond — custom formulated grinding wheels with a winning combination of durability, finish, and performance. 

The Resin Hybrid Series is the superior option of superabrasive diamond and CBN grinding wheels for the cutting tool industry. Using the latest Advanced Bond technology, competitive trials have proven that the bond grinds up to four times quicker without losing the wheel edge. Flute from solid, regrind, gash and end work, and relief. 

Resin Hybrid Bond is not your standard “one size fits all.” This bond is tailored to specific grinding applications, providing the highest quality tool with the most efficient performance. Its unique properties offer key advantages to the CNC Tool and Cutter Grinder in many ways:

• Free cutting action with superior form retention and surface finish 

• Self sharpening bond lengthens wheel life and dressing interval 

• High material removal rate with high temperature stability 

• Maximum heat dissipation with low and constant power consumption

• Optimal wheel profile stability lowers costs due to wear 

Previously cutting tool manufacturers had to commission custom-designed Resin Hybrid wheels to get all these benefits. Now CDT is stocking our most popular shapes and sizes specifically tailored to cutting tool manufacturing at affordable, off-the-shelf prices. CDT wheels are compatible with most of the cutting tool industry's leading CNC Tool and Cutter Grinder machinery.

If you are in the cutting tool industry and are interested in gaining a competitive edge with CDT's Resin Hybrid Series grinding wheels, contact our knowledgeable team of service techs today. Tell us your requirements and we will check our inventory for availability or provide you a custom quote. Wheels in stock ship the same day! 

Find My Wheel for same day delivery

Resin Hybrid — Now With Same Day Shipping!

Or call 800-443-6629.

Care and Maintenance of Diamond Wheels

Diamond wheels provide the maximum performance and high-speed cutting on demanding materials. Proper care and maintenance will ensure that the wheel gives the superior results for the maximum time. The steps are not difficult and well worth the effort.

Installation

Make sure that spindles, back plates and flanges are always clean before installing a new wheel. Use a dial indicator to check that the rotation of the wheel is within 0.0005 inch, 12.7 microns, of true. Tighten the flanges once the wheel is true and double-check tightness before use.

Diamond cutting wheels should only be used to make straight cuts. Twisting or jamming the wheel can cause fatigue and segment loss. Excess pressure should not be applied when making cuts. 

When performing any cutting or grinding process, all work materials require firm support. Excess overhang should be avoided; even slight tilting can create an angled cut. 

Feed and grinding speed

Material must be fed into the wheel at the appropriate speed. A feed rate that is too fast will cause chatter and vibration. This will result in a poor cut and possibly damage the cutting edge of the wheel.

Diamond wheels work best at speeds between 5,000 to 6,000 surface feet per minute. Running at lower speeds can lead to glazing.

Dressing

Using the wrong cutting wheel, one with a bond that is too hard for the working material, will create glazing. The easiest way to avoid this is using a blade that is matched to the material. Dressing the blade is a maintenance technique, but dressing does slow down production and reduce the life of the wheel.

Dressing a diamond wheel cleans the build up of debris from cutting operations that block the abrasive surface. The resurfacing restores the sharp abrasive edges of the diamond coating. A dressing stick, normally aluminum oxide or silicone carbide, is used to cut through or remove the debris and expose new diamond material. 

Make an arrow mark on the wheel showing the rotation direction the first time and always dress the wheel with it spinning in the same direction. Dressing a wheel in both directions will destroy it.

Dressing is accomplished by simply making a straight cut through the dressing stick or bar. Cut off a thin section per pass. Only one or two cuts through the stick should be required.

If a dressing stick is not available, a section of asphalt can be used. Make a few cuts into the asphalt and the blade should be clean.

Overheating 

Coolant should be used for maximum results. The coolant needs to spray to contact where the cutting wheel and material meet. A weak soluble oil solution may be used to reduce corrosion.

If dark streaks form along the sides of the cutting edge, the wheel is being overheated. Excess heat can cause the wheel to break apart. If dry cutting is being performed, allow the wheel to cool for about 10 seconds for every 30 seconds of cutting operation.

Use the right grade wheel, designed for the material to prevent injuries from reactive force or throw back. Never use a wheel that shows signs of fracture, fatigue or broken segments.

Industrial Diamond Facts

Diamonds are used for many industrial settings due to the fact that they are the hardest substance known. Diamonds are a crystalline form of carbon, capable of assuming a variety of shapes, sizes and qualities and are used for grinding, cutting, drilling, polishing and as an abrasive in industrial applications. Although diamonds have a high cost initially, they often cut down on the total labor cost of industrial projects due their efficiency for cutting and grinding.

SIZE AND QUALITY

Diamonds used for industrial purposes vary widely in cost which is based on two factors--size (determined by carat weight) and quality. One carat is equal to 200 milligrams of 1/5 of a gram. Each gram represents five carats. A carat is further defined as having 100 points (the smallest unit of measure in the carat system). Therefore .10 equals 1/10 of a carat, 1.5 equals 1 1/2 carats.

Diamond quality is difficult to assess, determined by highly technical factors representing the considered judgment of a trained diamond expert. For industrial purposes, the best way to judge diamond quality is by performance. The better quality a diamond is, the more structurally sound each individual crystal will be. High-quality diamonds have better shape definition, allowing for longer service and quality dressing action desired on the grinding wheel.

SHAPES

Industrial diamonds can be shaped in a variety of ways as shown below:

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Octahedron

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Dodecahedron

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Crystal

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Ballas

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Points

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Cube

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Macle

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Elongated

A Concise Guide to Single Point Diamond Dressers

Problematic grinding performance typically arises as a consequence of improper dressing. Choosing the correct diamond quality classifications greatly improves the expected quality of finished products. Moreover, the number of settable points will contribute heavily to acceptable dressing standards.

Classifications of Diamond Qualities

• Grade A quality diamonds provide four+ settable points--smooth-surfaced octahedron or dodecahedron.

• Grade B quality diamonds provides three+ settable points--possibility of inclusions, although they do not disturb the diamond's integrity.

• Grade C quality--two+ settable points exhibiting blockish structure with superficial irregularities. This grade is the most common grade used in tool rooms.

• Grade D quality--less than two settable points. Grade D's may have defects around less defined points.

• Grade E quality--one settable point, "utility" grade diamond typically presenting cracks and other flaws.

• Grade U quality--one settable point, "utility" grade cube-shaped diamond with an opaque surface

10 Tips For Using Single Point Diamond Dressers

1. Extend the life of a single point diamond dresser by inclining the tool at a 10 to 15 degree angle to the wheel radius. Point the tool in the rotation direction of the grinding wheel to maintain a consistently sharp point.

2. When dressing with Polycrystalline (PCD), grit, diamond single points or arbitrary stone tools, the infeed has to be .001 since a diamond dressing tool inevitably pulverizes the vitrified bond. Anything higher than .001 will cause cracking into the wheel--as much as .009 deep--that forces the bond to degenerate. In addition, gullets develop that produce loading by catching chips and overheating the wheel. Consequences of excessive infeed are chatter, bounce, bad finish and burn. 

3. Sharply-tipped, crystal octahedrons should be utilized for straight dressings. For 46 grit and 60 grit wheels, crystal octahedrons shaped in a gothic style work well. Points associated with crystal octahedrons stay sharp if you turn the tool six to 12 indexes every revolution, or as necessary.

4. Make sure to use enough coolant to moderate dressing temperature, otherwise overheating occurs which may chemically transforms diamond into graphite. Diamonds will also suffer cracking if subjected to large temperature gradients.

5. The objective of dressing is to generate and expose novel, superficial cutting edges on the wheel. Single point diamond dressers achieve this objective by shattering existing gravelly grains and facilitating the emergence of desired abrasive particles. Dressing increases in-feed as well as feed and must be performed regularly to maintain optimal grain protrusion and grain edge sharpness.

6. Always begin dressing at the center of the wheel, which is the biggest diameter. Starting a dressing procedure at a wheel's side will probably result in shattering or even destroying the highest quality diamonds. 

7. To prevent wheel taper, place the single point diamond dress as close as possible to the grinding area. 

8. Grinding wheel grain sizes are contingent on longitudinal feeds, which significantly influences the structure of the surface of a grinding wheel. Additionally, reduced feed rates will predictably provide finer, more desirable surfaces.

9. Rotate the dresser 20 to 40 degrees in the shank if a flat appears on the diamond so that the dresser maintains an optimally conical point. 

10. Avoid letting the diamond erode until the shank is visible. Doing so could allow the stone to dislodge or fall out.

The Plating Process - The How and the Why

Diamond tools come in many different styles. One of the more commonly used types of diamond tools are those that have been electroplated. Understanding what exactly electroplating is, how the electroplating process works and what these tools are used for is important - especially if you plan to use any type of diamond tools in your machining process. That way, you can determine if these are the right solution for your machining needs.

What is Electroplating?

Electroplating is the process where a metal object is coated with a thin layer of another metal using electrolysis. For most applications these metal coatings are thin, less than .002 inch thick. With diamond tools, a strong layer of metal tool is electroplated to bond a single layer of diamond to the tool.  This adds strength to the tool and additionally, it makes a tool that can grind even the hardest materials.

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How Does the Electroplating Process Work?

A solution is created using a “salt” of metal coating plus water. This is referred to as an electrolytic bath. The object or tool that will be plated is placed in the electrolytic bath. Then, a metal bar is added to the bath. It may be the metal used for plating or another material that isn’t affected (insoluble electrode). After this, the object is connected to a source of direct current and the bar is connected as well. Once power is applied, the electrolysis process occurs creating a plating. Multiple layers can be applied to achieve the desired levels of plate.

What Are Electroplated Tools Used For?

The electroplated tools are stronger than even standard tools or composite tools. With the right plating, an old, worn tool or wheel can be sharper and stronger than ever. These are used in machining mainly for grinding or cutting processes. These tools are used in the manufacturing of components for the auto industry, medicine, aerospace, computers and factory work. The strength, affordability and usability of electroplated tools make them highly desirable within all levels of the manufacturing process.

Now that you understand more about electroplating and diamond tools, it may be time to determine the best options for your business. CDT (Continental Diamond Tool) sells new electroplated diamond tools, or we can work with you to electroplate your current tools to help you accomplish more than you ever thought possible. Call or contact us to learn more about our services and solutions we would love to work with you!

Machining and Composite Materials - The Basics

Composite materials, which are sometimes called composition materials, are created by combining two or more materials that have a significantly different make up of chemical or physical properties. When these materials are produced, the material produced often has characteristics that are different from the component materials that create it. Composites are very popular today in the manufacture of a number of different products, and they will likely only become more useful in the future.

Manufacturers choose composites for a number of reasons. Generally, the purpose is to gain the benefits of two different materials for example a lightweight material and a strong material. Composites are used within a number of different industries. From tools to golf clubs to ceramics, composites are an excellent choice for creating top-quality products.

The one problem with composite materials is that the means of working with traditional materials often do not work with composites. Machining composite materials is a challenge that requires a powerful solution. Continental Diamond Tools (CDT) Diamond tools do just that.

There are a number of diamond tool manufacturers out there, but many do not produce a tool that is adequate for the needs of working with some of the more complex composite materials. CDT understands the complexity and problems you may face when you are working with machining composite materials. We stepped up our production to meet the challenge and developed diamond products and technology that is specifically designed for this purpose.

CDT’s plated process is perfectly suited for composites. Our diamond tools provide outstanding cutting speed and efficiency for even the trickiest composite. Additionally, our engineering team specializes in helping our customer create a successful and cost effective solution for manufacturing needs. Whether working with metallic or non-metallic composites, the CDT diamond tools will provide the best possible results each and every time.

No matter what type of composite you work with, from FRP to fiberglass to Kevlar® aramid fiber, our products are the perfect solution. CDT’s electroplated wheels are useful for all areas of composites, including: automotive, boating, aerospace, sporting equipment (golf clubs, archery equipment, bicycles and scooters, etc), wind energy, and military applications.

Instead of worrying that your current machine process won’t get the job done or will fail when you need it most, switch to a process that is proven to achieve results. Call or contact us at CDT to discuss the composites you process and your current machine set-up. We can help you find the perfect diamond tools that can grind and shape your composites just as required.

Why Cubic Boron Nitride Is Better Than Diamond for Grinding

Diamond grinding tools have always been an industrial mainstay but Cubic Boron Nitride (CBN) may be a better solution in many applications. CBN grinding wheels provide the same benefits as diamond tools and even perform better in some applications.

The desirable characteristics of any abrasive include:

• Hardness

• Strength

• Abrasion resistance

• Thermal and chemical resistance

• Ability to maintain sharp cutting edges during use

Hardness is perhaps the most critical property of every abrasive. Abrasives tend to lose hardness during application as a response to very high temperatures. One of the greatest advantages to using CBN is that it maintains its hardness at room temperature and over a wide variety of temperature ranges.

About CBN

CBN is the second hardest material after synthetic diamond. The process of making CBN abrasive is similar to that of synthetic diamonds: scientists treat hexagonal boron nitride at high temperature and pressure to create cubic boron nitride and treat graphite in the same way to create diamond.

About CBN

CBN is the second hardest material after synthetic diamond. The process of making CBN abrasive is similar to that of synthetic diamonds: scientists treat hexagonal boron nitride at high temperature and pressure to create cubic boron nitride and treat graphite in the same way to create diamond.

Machinists make CBN grinding wheels by plating CBN particles on steel, using plated nickel to hold grit in place. A single layer of CBN grit applied to the surface of a metal disc can grind even the hardest surfaces and last for years.

CBN has several attractive characteristics that make it superior to diamond:

• Withstands heat, especially during high-speed applications

• Does not cause grit that can dull bits

• Stays sharp and cool because it does not react with steel

Diamonds can also react with transition metals, limiting their usefulness for grinding certain materials. Cubic boron nitride is stable and does not tend to react unfavorably with standard transition metals.

But What About Diamonds? 

Diamond super-abrasive grinding wheels do have their advantages in some applications, especially in grinding abrasive or hard materials such as aluminum oxide, ferrites, ceramics, tungsten carbide, gray and ductile iron, and carbon. These grinding wheels also have the ability to cut freely with a cool cutting action, which is handy in applications where coolants could damage materials. Diamonds will likely remain a popular choice in many grinding applications in the future but nanotechnology may propel CBN into the top position.

Nanotechnology and CBN

In January 2013 issue of Nature, a scientist from University of Chicago’s Center for Advanced Radiation Sources and his colleagues reported they had been able to make ultrahard CBN by drastically shrinking grain size. The researchers were also able to rearrange the crystals into a zigzag formation of boron and nitrogen rather than in conventional flat layers to give it super resilience.

“Now, we can make this material as hard as single crystal diamond,” says the lead scientist, Yanbin Wang. “In some ways, it’s a better tool than diamonds, especially given its high fracture toughness.”

What to Look For When Choosing A Diamond Wheel Supplier

The suppliers your company chooses can affect your business in many ways. Qualities like expert support, competitive pricing and speedy turnarounds can make significant differences in your success. Continental Diamond Tool is a world leader in the field of superabrasives for industries that include medical tool manufacturing, construction and aerospace engineering. Our small company philosophies and big company capabilities mean that you are in the hands of ethical, hardworking and capable support. Among the qualities that set us apart from the rest:

Speedy Delivery

Every day your supplies take to get to you is one that can hold up your operation. And, when you deal with another grinding tool supplier, you can wait as long as two months for your custom equipment, leading to slowdowns and delays.

We maintain an extensive inventory of raw materials so that we can complete your order fast in our in-house manufacturing facility. These allow us to supply an unlimited number of superabrasive products that fit your needs, timeline and budget. Our average shipping time is between 15 and 18 working days. We are proud of ability to create tools to order at a speed that gets you back to work as quickly as possible, saving you from expensive downtime.

Helpful Technical Support

Our commitment to you doesn't end when our product leaves the door. We have highly trained and knowledgeable staff that can help you with every phase of production, from prototypes to replacements, to improvements and enhancements. We can help you determine which tools are best for the job, how to implement strategies to make your company's work more efficient. Reach out to us for the assistance that will help you overcome obstacles and clear your way to success.

Global Outreach

Throughout the world, we offer support and custom tools to get the job done. Through innovation and commitment to customers, CDT has become the global leader in superabrasives in a wide range of industries. Our small company values, dedicated technical support and outstanding lead times mean that you can be sure that you can get the tools you need wherever you need them.

Competitive Pricing

CDT produces custom diamond wheels at competitive prices. We help people in all industries keep their costs under control to improve their bottom line and make their businesses more profitable. Our sales and manufacturing team work together to ensure that you are getting quality tools at an affordable price.

Since 1973, CDT has been committed to supplying a wide range of industries with the highest quality custom diamond tools. Contact us today to learn how we can serve your needs.

Grinding Wheels in the Electronics Industry

Grinding wheels and grinding tools of all types play a huge role in the electronic industry - even in ways that many people might not realize. Metal bond grinding tools are used to create a large number of the types of products that we use and love on a daily basis. By taking a look at the types of electronics devices that these important tools help create, you can start to see just how integral of a role they play in life as we know it.

Grinding tools like diamond drills, scoring disks and superabrasive endmills are used during the creation of printed circuit boards, which are a key component to many electronic devices that we find in our homes. If you own a desktop computer, laptop computer, high definition television set or home theater system of any type, you have the advancements enabled by circuit boards to thank for the hours and hours of enjoyment that you have received from these types of devices.

The types of circuit boards that are commonly made using grinding wheels and other grinding tools in the electronics industry are called printed circuit boards. These specific types of deices support various electronic components using tracks and pads that are conductive, allowing electricity to flow from one part of the device to another. The types of printed circuit boards that can be made using grinding wheels of all types include multi-layer boards. Single sided boards, which is a printed circuit board with only one copper layer, and double sided boards, which are a type with two layers of copper, are also commonly made using grinding tools like diamond drills for maximum precision. These types of printed circuit boards are traditionally found in almost every consumer electronic product that you can purchase, except those that are so simplistic in nature that they don't need a circuit board at all.

Part of the reason why diamond drills and metal bond grinding tools are so important to the electronic industry is because of the types of materials that they are capable of processing. Diamond tools in particular are capable of processing carbide alloys, stone, ceramics, semiconductor materials, aluminum, copper, copper alloys, rubber and resin. These types of materials are all used throughout the electronics industry in varying degrees. Copper and copper alloys in particular are hugely useful to electronic devices because they are both incredibly conductive with regards to electricity and resistant to erosion. As a result, they are ideal for situations like copper wiring, like the type that is used to transmit high speed signals into a person's home from a cable television provider.

Grinding Wheels In The Medical Industry

The medical industry relies on both brand new technology and old world skills and knowledge to help keep people healthy and heal injuries. One of the devices used in medicine that truly bridges the gap between old and new is the plated diamond wheel and other diamond tools. This device can be used in a number of procedures as part of a treatment plan that includes both new and old techniques. Learn a bit more about the use of these tools in medicine and you are sure to appreciate their flexibility.

Creation of Orthotics

Today’s orthotics and implants are more advanced than ever before. Creating these custom pieces of equipment requires careful work and precise sizing. Using plated diamond wheels is one of the best ways to cut the metal and plastic pieces with the level of precision required for these devices. Do some research and you will quickly see that nearly all of these types of medical devices are created using diamond wheels of some type.

Bone Sawing

Working in the emergency room or operating room requires a steady hand and a lot of hard work. However, this work can be made much easier with the right equipment for the job. Sawing bone is something that must be done for many different procedures. Fortunately, a quality diamond plated wheel can be used to saw through the bone with minimal effort and the best possible results. A bone saw is one of the most important pieces of equipment in any high-tech medical facility diamond plated wheels are of the utmost importance

Dental Uses

Diamond plated wheels are used extensively in the creation of dental burs and other tools. Only with the best wheels can you get the best possible dental equipment. Additionally, diamond wheels are used for bone sawing in the mouth too as a way of reaching areas that require serious oral surgery.

Other Uses

These are just a few of the ways that these diamond plated wheels are used by those in the medical profession. You’ll find that many of the devices used in a modern operating room or doctor’s office are shaped and designed with the use of a grinding wheel. Without this technique, the medical procedures of today would be vastly different and likely not as effective.

Now that you better understand the different ways that diamond plated wheels and similar tools can be used in medicine, your appreciation for the products is likely enhanced. If you want to learn more, contact one of the leading diamond tool manufacturers Continental Diamond Tool. One of our experts will be happy to explain more about how diamond tools are used in medicine as well as in other industries. Plus, we can help you find the best products and solutions available from CDT saving you time and money.

The Best Grinding Tools for the Oil Industry

The grinding wheels used in petroleum engineering must be specifically developed to provide the performance needed for these applications. Common grinding applications in the oil industry include the manufacture of drill bits, gage blocks and wear parts. Superabrasives made from polycrystalline diamond (PCD) and carbide are common in this industry, especially for drill bits. Additional types of abrasives used on an oil rig include bonded abrasives and coated abrasives.

Benefits

The benefits of abrasives that have been custom developed for oil and gas applications include greater effectiveness, efficiency and tool life. Grinding tools need the latest bonds to deliver the precision needed for grinding the PCD and carbide bits used in modern drilling. These bits often use centerless wheels that offer a high cutting depth with high grind ratios, which cut costs during grinding operations. PCD abrasives are also used on tools that perform highly-efficient chamfer grinding.

Diamond Abrasives

Diamond abrasives usually refer to abrasives made with PCDs. They are most common in the manufacture of down-hole drill components such as drill bits made to gage. These bits are used in a variety of applications such as centerless, chamfer, form and surface grinding.

Bonded Abrasives

Bonded abrasives include resinoid abrasives and vitrified abrasives. Wheels that use these abrasives in the oil and gas industry can perform both precision and rough grinding applications. Components that are ground with wheels that use bonded abrasives typically have a hard face with a durable coating. These components include the following:

• Couplings

• Down hole stabilizers

• Frac pump plungers

• Pistons

• Polish rods

• Pony rods

• Reamer shoes

• Shafts

• Valves

Bonded abrasives often use proprietary bond and grain formulas to provide performance gains over traditional abrasives such as silicon carbide and aluminum oxide. These benefits include longer grind cycles and a net reduction in cost per part.

Coated Abrasives

Coated abrasives may be used in a variety of forms such as belts, discs, rolls, sheets and wheels. These products are typically composed of cloth, fiber, film and paper for applications that include rough grinding, finishing, lapping and polishing. Products that use coated abrasives can be found in virtually every segment of the oil and gas industry, including petrochemical plants, oil reserves, pipelines and rigs.

Structured abrasives are commonly used to create a consistent finish, while flexible abrasives provide excellent results in high-velocity oxygen fuel spraying applications. Coated abrasives with an agglomerate grain are often used to improve performance with non-woven products such as convolute wheels, belts and discs. Users who wish to lower their total costs for coated abrasive products should consider ceramic belts, flap discs and specialty discs.

Choosing the Right Grinding Tools for the Aerospace Industry

Abrasive technology is an important manufacturing process in many industrial sectors, including aerospace engineering. This technique requires the use of grinding wheels with coated abrasives such as diamond powder, which is extremely abrasive due to diamond's hardness. The best choice of material for bonding the abrasive material to the grinding wheel varies greatly and may need to be customized for a specific application. Diamond grinding creates surfaces with a smoother finish and sharper edges, which is often essential in aerospace research. Superabrasives provide better results in grinding operations that require greater duration, higher speed and cleaner cuts.

Hardness

The most significant factor in selecting the best abrasive material to use in a particular application is the hardness of the material being ground. The Rockwell hardness scales are the most common method of measuring hardness for these applications, especially the Rockwell C scale. This scale is commonly known as the material's RHC, which uses a 120-degree cone under a force of 150 kilogram-force to make an indention in the test material. The RHC measures hardness as a dimensionless number, with values between 20 and 100 generally considered reliable. Superabrasive grinding wheels typically become cost effective for materials with a hardness greater than 45 RHC.

Speed and Cutting

Grinding wheels have ideal ranges for operating speeds and cutting depth that primarily depend on the abrasive material. Diamond grinding wheels should operate at a surface speed between 3,000 feet and 8,000 feet per minute, such that greater speed is better for applications involving frequent interruptions or small areas of contact between the work piece and the grinding wheel. Operators should minimize the depth of the cut to create the best finish and extend the life of the work wheel. The maximum DOC for each pass depends on the particle size of the abrasive material. Abrasives with a grit size between 80 and 150 micrometers shouldn't cut more than 0.002 inches per pass, and abrasives with a grit size between 180 and 220 micrometers should be limited to 0.001 inches per pass. Grit with a size between 240 and 400 micrometers has a maximum DOC of 0.0005 inches per pass, and a 500 to 600 grit size has a maximum DOC of 0.0003 inches.

Bonding

The choice of bonding material is more complex than many of the other decisions involved in diamond grinding. The material comprising the work piece is a critical factor, as is the size of the abrasive particles. Aerospace engineers must also consider the operating speed of the grinding wheel and the type of coolant that will be used. Additional factors in selecting a bonding material include the type of bonding material and its hardness. Some grinding applications use electroplating rather than bonding to attach the abrasive material to the grinding wheel.

To find more information on which application is best for your project, contact CDT today.

CBN Grinding Wheel 101

Cubic boron nitrite grinding wheels are used for projects that require intricate attention to detail. They provide a high-quality tool that will help you produce a beautiful, well manufactured product.

What is a CBN Grinding Wheel?

A CBN wheel is made from cubic boron nitride. This material is one of the hardest materials available, second only to diamonds. The main feature of the material is that it features a high abrasion resistance and thermal conductivity that maintains its sharp cutting edges. It’s a great choice when doing advanced products that require a high attention to details.

Why Use This Type of Wheel?

CBN wheels are important for grinding HSS. This is because it's a better material for sharpening and for durability, one of the best available. Diamond is harder than CBN, but over time many people have discovered that diamond is not a suitable abrasive grain and isn’t a good choice when grinding on high speed dry wheels. Choosing to buy grinding wheels with cubic boron nitrate will offer you the durability you need, while giving you the finished product you desire.

Benefits of CBN Grinding Wheels

These types of wheels have an almost indefinite life span when they are properly cared for. Many have chosen to use these wheels instead of the normal granular wheel because of their durability. The strong nature of the wheels comes from the bonding that takes place between the grains and the supporting steel hub. Thanks to this bonding feature, the wheels can be used dry without any coolant. Only a small amount of pressure is needed to sharpen a tool. The grind is very fine and there are almost no sparks when used for sharpening, unlike similar grinding wheels. The wheel remains cooler than a conventional wheel as well, making it nearly impossible to burn the tools. Choose certified wheel suppliers when looking for a grinding wheel.

Why Buy Grinding Wheels?

Those who have used grinding wheels have seen the benefits of the strong material. The main advantages are that it doesn't heat up when used for sharpening, it provides a perfectly balanced wheel, and has a low risk of blowing up. When it comes to your projects, time, and money, these are benefits that soon become valuable.

Choose certified CBN grinding wheel suppliers when looking for a grinding wheel. You’ll save time and money when you choose a supplier that is well versed in the benefits.

The Right Tools for Every Application

It’s not the discovery and control of fire that really separated man from the other animals – it’s tool-making that truly took the human race out of caves and into civilization. Tools changed the course of human history, and today they are still at the heart of every great item made by the hand of man. When you want to make amazing products, you need truly amazing tools. Get the right abrasive grinding wheels for your metal-shaping projects and you’ve got the tools you need to make your business a success.

Certain manufacturing would never be possible without serious tools that do a tough job. We carry everything from mounted grinding wheels to plated wheels, machinery to suit any type of manufacturing project. Isn’t it time you add large company capabilities to your business’s resume?

Grinding Wheels for Maximum Productivity

If it’s maximum productivity you need, look for CBN grinding wheels. The metal bonding on these wheels creates a very tough tool that holds its shape even after hard use. They’re commonly used in wet grinding. They work well on glass, quartz, silicon, ceramics and many other materials, including optics. This offers very low-maintenance, high-quality machining.

Replating for Extended Use

Have a used grinding wheel diamond bonded tool replated for long use. Once the bond has begun to dull, send the tool back to us. On an affordable plan, it’s easy to have that tool replated so that it performs like new again. These tools have an aggressive bond to hold form even after lots of use.

Grinding Wheels for High Efficiency and Precision

Copper or phonelic resin is at the heart of resin bonded grinding wheels. Use these when you want high-efficiency equipment that works precisely and quickly. They self-sharpen, and despite the superabrasive grinding they tend to stay at low temperatures. Use these wheels to polish, sharpen or grind at will. Like bonded wheels, these tools perform well for wet and dry tasks. Use them for glass, alloys, ceramics and many other materials.

Carborundum — the trusted name in grinding wheels

Look for Carborundum grinding wheels when you want a trusted, name brand tool. It’s a well-known name in the grinding business, and their tools are available in many different sizes and types.

Get the quality superabrasive tooling you need in one week or less with our fast delivery policy. Start manufacturing like a large company at prices even small companies can afford. You need the right equipment for every job to get the right results. Start with a company that has all the right machinery. Start with technical experts at Continental Diamond Tool Corporation.

What should you look for in a grinding wheel manufacturer?

When creating intricate projects that require precision, you will need a quality CBN (cubic boron nitride) grinding wheel. To make sure you are getting a product that meets your needs and will stand up to the use that is required, you need to find the right CBN Grinding Wheel Manufacturers. Not all manufacturers are created equal, so be sure to do some research before choosing where you will purchase your next wheel. Keep the following tips in mind when you are making your decision.

4 ways to identify the best grinding wheel manufacturer

When looking for a grinding wheel supplier, you’ll want to keep a few things in mind. Remember, your project and product need a wheel that will create a high-quality product and you need a supplier that will get you the wheel you need quickly and correctly, with no hassle.

First, ask yourself the following questions:

• Is the supplier certified?

• Do they have satisfied customers?

• What kind of reviews is the supplier getting?

• Where do the grinding wheels come from?

Getting some simple answers before you buy will help save your time and money in the long run. Abrasive suppliers offer a wide variety of products for many different kinds of grinding applications. Choosing the wrong product can cost the supplier time and money. Choosing the wrong supplier will cost you even more time and money.

Choosing the right grinding wheel

Now that you know where you are going to buy your next cubic boron nitride grinding wheel, you will need to know how to choose the right grinding wheel. To identify a  quality grinding wheel, you should consider:

• Are the abrasive grains distributed throughout the wheel?

• What is the percentage of grain and bond? The percentages should be spaced throughout the wheel. The grains do the cutting while the bond holds the grain together.

• What shape of wheel do I need? Most wheels come as a straight wheel. The grinding face is on the periphery of a straight wheel. Another variation of the straight wheel is the recessed wheel. The right grinding wheel supplier will have a knowledgeable customer service department that can assist you in finding the right wheel for your needs.

Other grinding wheel purchase considerations

The grinding wheel is only one component of a well engineered machine. The wheel, work material, and the working function all combine to create the tool needed for your job. Buying Diamond grinding wheels for carbide takes some time and attention. Be sure to do the research needed before making the investment. Choose the grinding wheel that is best suited for you needs, while taking into account all the components of the process.

Get a custom quote from an experienced supplier of cutting and grinding products now.

The Perfect Cut

Many industries call for the careful touch achieved by diamond-based tools. When you're in the market for a diamond saw blade manufacturer with whom you can build a successful relationship, make sure you go with a versatile company. You need someone who knows the ins-and-outs, not just of diamond saw manufacturing, but also of its uses and benefits. In order to understand all the advantages, you need an expert well-versed in the many uses of diamond tools.

When customers ask why they need to buy diamond saw blades above all others, versatility is generally the answer. In those industries where a perfect, polished cut is top priority, nothing does it better than diamonds. Because diamond plated and tipped saws grind rather than hack or cut, they lead to a smoother finish. For materials that leave no margin for error, such as marble and granite, composite materials, certain metals, quartz, ceramic, and fiberglass, mere cutting can ruin the finish. Always choose to buy diamond blades, as the super abrasive grinding creates a cleaner, more flawless edge.

The versatility of diamond tools continues. Be aware of the benefits of using a continuous rim diamond blade on wet and dry materials. In fact, using a diamond blade on wet or damp materials sometimes leads to a better, smoother cut. With concrete, granite, and certain kinds of marble, especially, wetting down the material is widely understood to create better results. However, when manufacturing medical tools, working with quartz or fiberglass, or dealing with carbine, a dry grind promises a look that is just as clean and smooth.

It's easy to see why it is so essential to choose a relationship with an expert company. Better still, look for manufacturers of diamond blade saws who guarantee quality work and understand the importance of quick delivery. A speedy turn-around practically ensures repeat business as everyone will be both happy and fully satisfied. It's a win/win situation for everybody. That's why it's essential to forge a solid relationship with a quality manufacturer who will get you the machines you need.

Diamond tip saw blades are the standard in many industries, especially those which depend on professional grade work with no mistakes. Whether you're making a memorial or working on the latest medical innovation, you want flawless craftsmanship created by a company that stands by its work, promises remarkable customer services in all areas, and understands how to manufacture solid, efficient diamond-based tools.

To get your custom quote, click here.

What do Scientists, Construction Workers and the Medical Industry Have in Common?

It sounds like a joke: What do scientists, construction workers, and the medical industry have in common? The answer is diamond cutting blades that let each do extraordinary jobs to make the world a better place. From shaping gemstones into dazzling creations that fit on the most slender finger to grinding through asphalt and concrete to make way for a new mall, these diamond cutting tools represent a marriage of power and precision. 

When selecting a diamond cutting blade for a particular job, there are several things you should consider. First, what type or shape of diamond saw blades will work best? The circular blade gets wide usage because it handles so many tasks with ease. It’s also available in extremely slender forms. On the other hand, specialized diamond cutting tools work better for certain jobs. For instance, working with a gemstone requires smaller tools, so bonding diamonds to a thin wire is necessary.

You also need to think carefully about the kind of bond you want for your diamond cutting tools. The bond refers to the powder metals that hold the diamond to the base, and the bond is either soft or hard. Though it might seem a bit counter-intuitive, you want a soft bond on the diamond cutting blades when you’re grinding through very tough material. The softer bond falls away more quickly, allowing new diamond edges to make frequent contact with the material you’re cutting. By creating contact with newer diamond surfaces that are sharp, the diamond saw blades make a better go of cutting up hard material. Don’t forget to consider what size diamonds you need, what concentration of diamonds you need on the blade, and their toughness. Take your cues from the material you’re cutting as you choose the right diamond cutting disc for the job.

Regardless of what kind of work you’re doing, consider whether you need to use water with your diamond cutting wheels. Water reduces dust flying into the air during grinding. It also cools the diamond saw blades and helps give these blades longevity. So, usually, it’s advisable to use diamond cutting tools wet and not dry.

When ordering a diamond cutting disc, be sure to request the correct diameter, blank thickness, arbor hole, and slots. In addition, consider adding diamond plated ribs to your blade to reduce wear and help with side cutting. Also specify the kind of edge you want, either round or square, for your diamond cutting blades. Ask about any special requests you have about tolerance and the thickness of the cut.