How to Extend the Life of Your Electroplated Grinding Wheel

CDT offers what’s called the “Strip and Replate” Program, designed to give our customers the highest quality grinding wheel abrasives for the longest time possible, in the most cost effective way for the customer (more on this in a moment)...

First, let’s cover when you’ll want to opt for this program, and how it works.

Stripping and replating a grinding wheel refers to the process of removing the old, worn-out abrasive material from the surface of a grinding wheel and replacing it with new abrasive material.

When customers opt in for this program, we work with you to create customized tooling that you will be able to use and then bring back to CDT for us to return it to “like new” condition after it begins to wear. This keeps your wheel fresh and performing at optimal levels without having to buy new.

When To Strip and Replate?

There are many reasons why you may need to replace your wheel with new abrasive, including:

• The particles on the surface of your abrasive get clogged (potentially from metal shavings or debris from the grinding process)

• Your wheel becomes dull from the worn out abrasive

• You need to switch from grinding one material to another, and the new material requires a different type of abrasive to be put on your wheel

• The grinding wheel has worn down unevenly, causing vibrations and reducing your wheel’s effectiveness

How Does The Process Work?

CDT is able to provide high quality strip and replate services through strip technology that will remove the remaining abrasive on your worn down wheel without damaging the surface finish of the core.

Electroplating involves depositing a thin layer of metal and abrasive particles onto the surface of a grinding wheel by using an electrical current in an electrolytic plating solution. 

When a grinding wheel has reached its life, we remove the old abrasive material on your wheel by soaking the wheel in a chemical solution that will safely dissolve the deposited plating without damaging the integrity of the core. 

Once the old deposit and abrasive have been removed, we apply a new layer of abrasive material through the electroplating process.

After the new abrasive material has been applied, the grinding wheel is re-balanced to ensure you continue to have smooth operation and optimal performance with your returned “like new” wheel.

When is An Electroplated Grinding Wheel The Best Choice?

Electroplated grinding wheels are considered the superior choice for applications that require complex shapes or geometries. Some specific applications include metal cutting tools, saw and knife sharpening, PCD grinding, and surgical tool blade sharpening – among others.

They’re used in a wide range of industries, including metalworking, woodworking, glass and ceramics, aerospace, automotive, medical, and electronics manufacturing. 

Common materials that are compatible with an electroplated diamond grinding wheel include: 

• Cemented carbide

• Glass

• Ceramics

• Fiberglass

• Plastics

• And more

Whereas common materials that are compatible with an electroplated CBN grinding wheel include:

• Die steel

• Hardened carbon steels 

• Hardened stainless steels 

• Alloy steels

• Aerospace alloys

• And more

When you add in the ability to strip and replate, it makes electroplating a superior choice in many ways:

1. It provides a more consistent and uniform distribution of abrasive particles on the surface of your grinding wheel, which can help ensure consistent grinding results and prevent uneven wear in the future.

2. Electroplating creates a strong bond between the abrasive particles and the wheel substrate, which helps prevent the abrasive from separating or shedding from your wheel during use. 

3. It can be used to apply a wide variety of abrasive materials, including diamond, cubic boron nitride (CBN), and various types of abrasive grains – and it can be used with both brittle materials and soft metals.

4. Stripping and replating an electroplated grinding wheel is a relatively quick and straightforward process because they are a single layer wheel. It also allows for precise control over the thickness of the abrasive layer, making it an ideal choice for achieving any customizations you may need for your wheel.

5. Electroplated wheels can withstand heavy use and provide consistent grinding performance. They don’t need to be reconditioned as frequently as other types of grinding wheels, making them a more cost-effective choice in the long run.

Overall, opting for an electroplated grinding wheel to be reconditioned and used again through the CDT “Strip and Replate” Program can result in 40% more in savings, with consistent performance results, rather than opting for brand new plated products.

If you’re ready to learn how CDT can work with you for a customized electroplated grinding wheel that qualifies for our “Strip and Replate” Program, click the button below to request a quote!

The CDT technical team is ready to provide abrasive solutions to your questions that will increase your performance while reducing waste.

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.

Meet The Next Generation In Hybrid Bond Technology: Ultra High Performance Grinding For The Cutting Tool Industry

At Continental Diamond Tool we are proud to announce that we have officially unveiled our latest breakthrough technology in hybrid bond products – the EVO Hybrid Bond – at the much anticipated Precision Machining Technology Show this past April 2023. 

What is EVO Hybrid Bond?

A game-changer in the precision grinding industry, EVO is a custom-designed bond that delivers ultra-high performance results that are impossible for our competitor’s standard Resin Bond wheels to match. 

This bond is a new and improved version of CDT's Resin Hybrid Bond, designed specifically to cater to the needs of Tool and Cutter Grinding.

One of the key benefits of EVO is its superior performance that helps produce high-quality cutting tools faster and more efficiently than its past versions. 

The bond is uniquely formulated to achieve faster cycle times without compromising on the wheel edge, making it an ideal choice for:

• Flute from solid

• Regrind

• Gash and end work

• And relief

What are the benefits of EVO Hybrid Bond?

When you opt for CDT’s EVO Hybrid Bond technology, you can expect superior results in both form retention and surface finish because of its free cutting action.

Additionally, the EVO bond is self-sharpening. This type of technology ensures the life of your wheel is longer-lasting, as is the dressing interval. 

It can also withstand much higher temperatures while still maintaining its stability, which makes high material removal rate not only possible, but incredibly precise.

Because CDT’s EVO Hybrid Bond offers excellent heat dissipation capabilities (while ensuring low and consistent power consumption) it enhances your overall efficiency and productivity of the grinding process.

It’s also a much more sustainable option. The wheel profile lends itself to a longer-lasting type of technology that reduces your grinding process costs in the long-term.

What sets EVO Hybrid Bond apart from the competition?

Beyond all of the benefits listed above, what sets EVO apart from other superabrasive grinding products is its unique blend of Resin Bond and Metal Bond. 

Available exclusively through CDT, this customizable type of bond is designed specifically to deliver cutting edge results that standard wheels cannot hope to compete with.

For the high precision cutting tool industry, EVO is a long-awaited solution to many common grinding challenges.

The bond offers a faster cycle time, less dressing, and greater performance. It is an ideal solution for those looking to improve their grinding process and achieve their goals.

At CDT, we are committed to providing the latest technology solutions to help the precision cutting tool community overcome their machining challenges. EVO Hybrid Bond is a testament to our commitment, and we are confident that it will transform your grinding process and help you stay ahead of the competition.

Haas Automation Machinery Features Continental Diamond Tool’s CNC Department

CDT is proud to have been recently featured by Haas Automation in their latest “Insider” video, showcasing the way in which our CNC department currently uses Haas machinery to produce high quality, customized results for our customers.

What does CDT’s CNC Department do?

The CNC department at Continental Diamond Tool (CDT) is responsible for using computer numerical control (CNC) machines to manufacture and grind diamond and CBN cutting and grinding tools. 

CNC machines use pre-programmed instructions to control the movement of tools and workpieces, allowing for precise and consistent manufacturing of complex parts and components.

In total, the CNC department supports 5 different aspects of CDT:

• Electroplated bonds

• Metal bonds

• Resin bonds

• Vitrified bonds

• Diamond rotary bonds

This involves using specialized tooling and fixtures to precisely machine and grind the wheel bodies, which are then bonded with diamond abrasive material to create finished grinding wheels.

The CNC department at CDT plays a critical role in ensuring the quality, accuracy, and consistency of our products, which is why using the proper machinery is so important.

Our CNC department frequently assesses the reliability and efficiency of all machines used to ensure that the quality and dependability of our product remains unmatched.

What HAAS machinery does CDT use?

CDT uses HAAS machinery at both our New Haven location as well as our facility in Europe. 

President of CDT, Nick Viggiano, says, “We bought our first 3 ST-10s about 12 years ago… Within around 3 months after that, we were purchasing a Mill and an ST-30 – and it continued to grow from there. Now we have close to 70.”

Haas offers ST-10s all the way up to ST-40s, which CDT has several of.

As far as Mills, CDT uses the VF8s, but uses some of the smaller ones as well.

Ron Fuller, Lead CNC Lathe Operator, says, “The greatest feature to me for my production rates and efficiency is the dual spindle aspect of these machines. It allows me to set the machine up and get it running and not have to stand there physically and operate the machine myself.”

The dependability of these types of machines allows the CNC team at CDT to streamline the grinding process for efficient and productive results. By not having to babysit machinery, time is freed to attend to other areas of the grinding process.

How does this type of machinery benefit the CDT customer?

Using Haas machinery is one part of many under the overarching CDT mission to provide exacting customizations for each of our customers' requests at the highest standards possible. 

By using machinery from Haas, as well as other reputable machinery producers, CDT is able to uphold this commitment.

The CNC team is committed to using the best machinery possible for each part of the process that will boost productivity and make it as cost effective for the customer as possible.

“Haas is one of many reputable machinery producers that CDT works with. They’re really great in supplying us with the tools we need to produce the high quality, customized products that our customers ask for.”

— Josh Werling, CNC Department Foreman

To learn more, check out the Haas “Insider” video below, and see how the CNC department at CDT uses these machines for different customization types.

Consort Precision Diamond To Participate In The LEAN Programme

Consort Precision Diamond, a leading manufacturer of precision diamond tools, is thrilled to announce its participation in the LEAN Programme! The LEAN Programme is an initiative that aims to help businesses in Wales achieve sustainable improvements in competitiveness. 

It is specifically designed for businesses that want to learn more about the principles of lean management, and is an intensive five-day programme that provides its attendees with a solid working foundation of both management principles and techniques. 

During the programme, participants learn how to: 

• Identify and eliminate waste

• Improve processes

• Increase efficiency

• And engage and empower employees to be more active participants in their roles 

All the subjects offered above are possible due to the collaboration between the Welsh Government and the Toyota Lean Management Centre in Deeside. The principles are taught through a mixture of: 

• Classroom theory

• Immersive shop floor observation

• Examples of practical application - all delivered at Toyota’s Deeside engine facility

• And worksite coaching at participant company sites to support productivity improvements

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"We’re really excited to be participating in this programme, and to have that opportunity to learn from some of the best in the industry," says Justin Hughes, one of the two employees from Consort who will be attending the programme. "This is a great opportunity for us to improve our productivity and competitiveness, and we are looking forward to applying what we learn to our work at Consort.”

Gareth Clifton, the other employee attending the programme, agrees. "We are very grateful for the chance to participate in this programme," he says. "This is definitely something that will not only help us improve our general skills and knowledge, but also contribute to the growth and success of Consort as a company, and that’s something we are always striving for. Can’t wait to hit the ground running when we come back from this experience."

At the end of the programme, participants will have a clear understanding of how to apply these principles to their own businesses. They will be able to implement sustainable improvements in the company’s productivity and competitiveness. 

In addition, they will have the opportunity to network with other participants during the 5-day event and learn from their experiences, as well as receive ongoing support from the Toyota Lean Management Centre to help them continue to improve their business. 

Consort has signed up to take part in the next available LEAN Start Programme, which is scheduled to begin in May 2023. 

As a subsidiary of CDT, Consort is committed to delivering the same high-quality products and services to its customers as CDT. The LEAN Programme is an important step towards achieving that ongoing expectation for growth, and we wish Justin Hughes and Gareth Clifton the best of luck at this programme!

Consort is looking forward to applying the principles and techniques learned from the programme to drive continuous improvement within the company. In doing so, it will continue to put Consort and CDT on the map as the highest-quality, highest-performing company for our customers to continue receiving exceptional results when they choose us for their project needs.

We cannot wait to continue serving you to the highest possible degree!

To learn more about this unique programme by the Toyota LEAN Management Centre, click here.

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.

Consort Precision Diamond Celebrating 5 Years With CDT

5 years ago, Continental Diamond Tool made one of our biggest leaps into providing top notch products for our customers by joining forces with our subsidiary – Consort Precision Diamond (CPD) – in the U.K.

CPD is a leading supplier of precision Rotary Diamond Dressers for production grinding applications in aerospace, automotive, medical, tooling, etc.

CPD has and remains fully dedicated to this passion – to provide all customers with the best rotary dresser technology possible.

When it comes to Rotary Diamond Dressers, their focus is all-encompassing:

• Design

• Process & Product Development

• Manufacture

• Application Support

By teaming up with CPD, CDT has been able to bring quality rotary diamond dressers to the portfolio of superabrasive product offering, allowing for a fully integrated grinding process to the customer.

This has led to superior results for grinding wheel maintenance. The Rotary Diamond Dressers:

• Can perform at high dressing speeds

• Capability improvements -0.001um tolerance

• Allow for more complex configurations

• Improved product performance

• Capacity expansions

• Additional Products - CVD / Traverse disc dressers

Not only does it make way for excellent sharpening and fine finishes, it’s cost effective too.

But we’ve been up to more than just producing the highest quality rotary diamond dressers these past 5 years… All of which has had a direct, positive impact on the service you’ve come to expect with us at CDT.

More has happened over the past 5 years.

Capacity Expansion (2019/2020)

With the help of the Welch government we invested $500k into CPD.

• New lathes

• New grinders

• New inspection lab/equipment

This improved our product quality, increased our capacity, and allowed us to hold tighter tolerances.

Major Upgrades to The Plating Lab 

With the increase in demand, and our drive to supply the best of leading edge tech, we launched an upgrade to the plating lab in 2021.

This extension more than doubled our ability to produce high-quality tight tolerance reverse plated rotary dressers.

Featured In the British Chamber of Commerce Study

The British Chamber of Commerce published a case study featuring CPD and our growth in international trade.

We export to over 20 countries worldwide, including:

• Europe

• USA

• Canada

• Brazil

• Mexico

• China

Nominated for 2 Major Awards

CPD was nominated for the 2022 Chamber Business Awards and the WCNW Chamber Business Awards in Export & International Trade.

2x Faster Production Rate

CPD expansion was supported by the government of Wales with £200k.

This support helped protect/create new jobs and would “help fund the first phase of a five year plan that will see Consort Precision Diamond expand and increasing its head count.”

2023

CPD will be adding a new product line of electroplated grinding wheels in Q2, which will allow further expansion into the superabrasives products in the EU/UK markets.

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CPD had championed so much in the past 5 years, maintaining and exceeding expectations for being the top producer of diamond rotary dressers.

Thanks for joining in the 5-year celebration with us! We expect even more great things in the coming 5 years.

To get a full look at all Consort Precision Diamond services, click here.

7 Reasons Why Vitrified CBN Grinding Wheels Surpass Conventional Grinding Wheels

A vitrified CBN grinding wheel is a superabrasive grinding wheel made from a Cubic Boron Nitride abrasive in a porous – or “vitrified” (ceramic) – bond. 

Vitrified CBN Grinding wheels are the most cost effective solution for production grinding of ferrous metals and aerospace alloys, and offer far superior performance when compared with conventional abrasive grinding wheels.

Especially for those in industries such as:

• Aerospace

• Automotive

• Bearing

• Medical

• Gears

• Mold & Die

• Round Tools (drills, reamers, taps, etc)

• Cutting Tools

So why exactly is that?

There are 7 critical reasons why making an upgrade to a CBN grinding wheel can make a huge difference in your industry.

1. 100 - 300x The LifeSpan

CBN abrasive is the second hardest material known to man and is 2 ½ times harder than Aluminum Oxide. Because of its high hardness, the CBN crystals offer 100-300 times the lifespan when compared with traditional grinding wheels.

While Vitrified CBN grinding wheels may cost up to 10 times that of a conventional wheel, the extended wheel life far exceeds the initial wheel cost, making it more cost effective. You get what you pay for – and this is definitely one of those products where you’ll quickly see the difference in its longer lasting abilities as compared to your old grinding wheels. 

(We’d even argue that once you’ve used a CBN grinding wheel, it’s hard to go back – it’s just that big of a difference).

2. Reduced Thermal Damage

Because CBN abrasive has almost 50 times the thermal conductivity of conventional abrasives, it transfers the heat generated from the grinding process away from the workpiece, rather than being absorbed by the workpiece. 

Combining the high thermal conductivity of CBN with the porous vitrified wheel structures, most heat is efficiently removed through the wheel and coolant, preventing heat damage to your workpiece.

With efficient removal of heat, your workpiece won’t be subject to thermal degradation or changes to the material properties – which is very important for improved wear and life of each  component.

3. Optimize Your Grinding Process

With high life and improved thermal properties, Vitrified CBN can be pushed harder during grinding, and decreased grinding cycle times are able to be achieved.  

As a result, the grinding process can be more readily automated. This creates less need for more grinding machines, floor space, wheel changes, waste generation, and operators – which has many advantages when it comes to your time, cost, and safety measures.

4. Customizable

Vitrified CBN grinding wheels are engineered per specific customer applications so you can achieve optimal performance. 

Considerations that can be taken into account include: material being ground, grinding machine, coolant type and delivery, dressing method, stock removal, quantity of parts, etc… And aggressive, free-cutting bonds can also adapt to various spindle speeds. Which is not only convenient, but also cost effective. 

5. Lights Out Operation

Vitrified CBN grinding wheels have “dressable” structures – which lend them to “lights out operation.” The grinding layer can be refreshed using a rotary, and in some cases, stationary dresser.  

You’ll be able to automate every step of the manufacturing process, making Vitrified CBN grinding wheels an excellent choice for production based applications.

6. Re-Truing of Formed Profiles

Another benefit of having a “dressable” structure is that complex forms and geometries are able to be generated in Vitrified CBN grinding wheels. The profiles are able to automatically regenerate in line on the properly equipped grinder and maintain tight tolerances.

7. environmentally friendly

The use of Vitrified CBN wheels (as opposed to conventional abrasive wheels) results in significant reductions in waste generation. It decreases the amount of grinding debris (swarf) >99%. 

It even allows for more recycling of the metal swarf that is generated because it is oftentimes free of grinding wheel breakdown. Many customers are able to get credit for the Environmental and waste reduction initiatives under ISO14000 and other programs.

Experience the cost effective solution for production grinding with Vitrified CBN Grinding Wheels. Contact us for your free quote.

Why Different Materials Need Different Grinding Wheels

With all of the grinding wheel options available, figuring out which one is going to be the most efficient and cost effective for your working material can feel overwhelming, to say the least.

This article will help cover the basics as to why different materials will need different grinding wheels - and how to select the appropriate abrasive type for your grinding wheel.

So why exactly do different materials require different types of grinding wheels?

It comes down to the material properties (i.e. material hardness and chemistry) and the proposed grinding process: factors like machine, coolant, dressing, stock removal, etc.

First, consider which type of abrasive will be best for your material: conventional or superabrasive?

Conventional Abrasives

• Aluminum Oxide

• Silicon Carbide

Aluminum oxide has a hardness of 1800 HrV and is commonly used in grinding of ferrous or other materials that are known to chemically react with carbon.

Silicon carbide has a hardness of 2800 HrV and is used on "hard" materials such as glass, ceramics and non-ferrous metals such as aluminum and copper.

Superabrasives:

• Diamond

• Cubic Boron Nitride (CBN)

Superabrasives are both harder (longer lasting) and have much higher thermal conductivity (remove heat of grinding more efficiently) compared to conventional abrasives.

Diamond is the hardest known substance with a hardness of 9000 HrV and is the most effective abrasive in grinding of materials that don't react with carbon such as glass, ceramics, and non-ferrous metals. It can increase wheel life by several orders of magnitude when compared with conventional wheels. Advancements in production of synthetic or man-made diamonds have brought their cost down and led to expanded use. We commonly see diamonds used for grinding tough materials such as very hard steels, cemented carbide, and aluminum oxide cutting tools.

CBN is the second hardest known material at 4500 HrV and is ideal for grinding ferrous metals and other materials that are known to react with carbon. It is commonly utilized in the grinding of high-speed steel, hardened cast iron, tool and die steel, and stainless steels. When appropriately specified and optimized, CBN can outlast conventional Aluminum Oxide wheels by a factor of up to 300:1.

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NOTE: With so many benefits, you may be wondering “What type of materials cannot be ground on a grinding wheel?” Superabrasives (Diamond & CBN) are focused on hard materials. We turn to CBN for hardened ferrous alloys, stainless steel, and nickel alloys. Diamond is ideal for even harder materials such as glass, carbides, and ceramics. The harder the material, the better it is for grinding with superabrasives, which is what we customize for our clients at Continental Diamond Tool.

You often cannot justify the cost of a superabrasive grinding wheel for soft nonferrous metals (<30 HrC) like aluminum, brass, and copper. Materials with such soft properties tend to “clog'' and coat the wheel and would require continuous dressing.

Some have asked, “Can you use a superabrasive grinding wheel on wood?" Wood is a very soft, inexpensive substance and would not be well suited for superabrasive grinding. For similar reasons, we do not recommend superabrasive grinding wheels for other soft nonmetallic materials like fabric, leather, certain plastics and rubber, etc.

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Now that you know the differences between Conventional and Superabrasive grinding wheels, you can see how each caters better to different materials and uses. Once you’ve narrowed down the proper abrasive type, a grinding wheel expert can help you narrow your selection further with a selection of different bond types, such as Resin Bond, Metal Bond, Vitrified Bond, and Electroplated.

The bond is what holds the wheel’s abrasive grains together. The strength of bonding of a grinding wheel is often referred to as its hardness. Generally speaking, grinding wheels with a higher grade or hardness are recommended for softer materials and vice versa. It is also now possible to combine bonds to form custom hybrid variations that have unique properties.

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NOTE: You may be thinking “Why do we use hard wheels for soft materials in grinding?” This is a complicated subject with the actual grinding mechanism (chip formation) being different between ductile or soft metals and hard materials like ceramics. Grinding wheels for metals act like micro-cutting tools where metal chips are cut or torn away. The chip size and shape is dependent on the material properties.

With harder materials such as carbides and ceramics, there are brittle fractures where small chips are actually fractured away in the grinding process. The material itself is very abrasive. Because the chips in carbide and ceramics are so abrasive, softer wheels are often more efficient at removing the small abrasive chips (a.k.a. swarf).

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When shopping for a grinding wheel manufacturer, it’s helpful to have some basic parameters handy to get the most accurate quote and best product for your application. For a whole list of considerations to bring with you for selecting the best grinding wheel, check out our article on How To Order Custom Grinding Wheels.

Then contact us to collaborate with our engineers, product managers, and technical sales people to go over all of these considerations with you. If you’d like, we can even come to your facility to review your process first hand and make recommendations.

When you have the optimal grinding wheel for your material, you will see the difference in speed, durability, and performance.

Choosing the Right Grinding Wheel

Choosing the right grinding wheel for any given project is perhaps the MOST important part of the process… But why?

It’s because choosing the WRONG grinding wheel for your material can be catastrophic for a whole host of different reasons. It can lead to:

• Significant amounts of money lost

• Major time delays to complete your project

• Workpiece and/or machine damage resulting from running the wrong wheel or grinding process.

• Alterations to workpiece properties (i.e. changes in material hardness from grinding).

That’s why it’s so important to go over your options carefully, and discuss them with your technicians and engineers to ensure your grinding wheel is going to get you the most bang for your buck, the fastest completion time possible while still providing high quality results, and will be safe for all workers involved.

So what exactly is a grinding wheel used for?

You can think of grinding wheels as really really souped up sandpaper… Just like sandpaper helps smooth a surface or remove excess wood, a grinding wheel is an abrasive that’s used to:

• Remove any unnecessary material

• Create a specific shape

• Grind down your material

• Prepare metal for proper welding 

However, unlike sandpaper, grinding wheels are effective on many materials in addition to wood. Grinding wheels are most frequently used for almost any type of metal material you’re working with – and they produce results at a MUCH faster rate than precision cutting, saving you time and money. They can even be effective at grinding plastics, glass, and non-metallic materials.

How do you choose what kind of grinding wheel to use?

You should consider what type of material you have that needs to be ground. 

The grinding wheel you choose needs to be made of stronger material in order to have an impact. Different grinding wheel types will produce different results. 

For example, if you were choosing a knife to cut a loaf of bread… A serrated knife will produce a cleaner cut than your butter knife. 

Choose the material that will give you the cleanest, smoothest outcome. 

Here are some other key things to discuss with your engineers to make sure you select the best kind of grinding wheel to use for your project:

• What material is being ground?

• What abrasive type should be used for that material?

• What size abrasive should be used (grain attribute)?

• How course, medium, or fine should the abrasive material be (grit size)?

• Coolant Type (if any)?

• And what bond type should be used?

Our team can help you review your equipment and processes, the parts you’re looking to grind, and provide recommendations (including whether or not a custom superabrasive grinding wheel is necessary for your unique project needs).

When should you invest in a custom superabrasive grinding wheel?

Custom superabrasive wheels are usually either made with diamond or from Cubic Boron Nitride (CBN). 

If your material that needs grinding is made of iron or other alloys, then a superabrasive CBN grinding wheel is your best pick. If your material is made of carbon, choosing diamond can help sharpen. Or if you have material made of granite, choosing diamond can help create a glossier finish.

Essentially, superabrasives are made from some of the hardest materials mankind can make. Traditional abrasives (such as aluminum oxide or silicon carbide) are much softer materials that can break down much quicker.

And while traditional abrasives may be less expensive, if you’re in any of the following industries, using a superabrasive will bring you the best, safest results:

• Aerospace

• Automotive

• Medical

• Electronics

• Composites

• Oil Industry

CDT is proud to have a strong group of engineers, product managers, and technical sales people in our back pocket who are more than happy to go over all of these considerations with you. You can come to our offices, or we can come visit your facility. 

Diamond Rotary Dressers by Type

Industry's increasing demand for high-accuracy, high-speed production has fostered a new branch of engineering technology to ensure grinding wheels are maintained in optimum condition. Diamond Rotary Dressers are now recognised as the most efficient and economic means of dressing and truing grinding wheels to the correct form, tolerance and condition. Their use is growing rapidly in the manufacture of components for automotive, aerospace, power generation, machine tool and precision engineering industries.

Leading in innovation

At Continental Diamond Tool Limited, we have been a frontrunner for decades in innovating rotary dresser technology. As far back as 1995, as Consort Precision Diamond Company, we won industry awards for our development of the high speed plating process which dramatically reduced previous lengthy plating times and is still in use today. We proudly holds the ISO 9001:2015 Registration Certificate for its Quality Management Systems, and we are continuously innovating to increase the efficiency and cost effectiveness of this industry-changing technology.

OUR FOUR MAIN PROCESSES

There are four distinct methods we use in the manufacture of our diamond rotary dressers: reverse plated, hand-set sintered, cvd sintered, and random set sintered. Each has its own benefits, as outlined below.

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Type 1 - Reverse-Plated

The High Accuracy dresser

Reverse Plated Dressers are selected where high accuracy of profile detail is required together with a correspondingly high quality surface finish on the component.

Accuracy is achieved by centrifugal dispersion of the specially selected diamonds onto the walls of a mould. These are secured by our electro-deposition process that has won acclaim through the acquisition of industry awards, thereby achieving the short lead times so often required by customers.

The electro-deposition process is stable and unaffected by shrinkage, which results in Rotary Diamond Dressers of exceptional accuracy.

Tolerance Detail

General Surface Finish Produced: 0.4uM. 16 C.L.A.

Typical Applications

• Turbine Blade - Fir Tree Root Form

• Cam Grinding

• Bearing Industry

• Ball Joints

• Needle Injectors

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Type 2 - Handset Sintered Dressers

A CONSORT PRECISION™ SPECIALTY

Of all the rotary dressers for which the Consort Precision name is known, Handset Sintered Dressers are our most popular type. These custom diamond rotary dressers cover many applications where robustness is required and the general tolerance is open.

As the name implies, diamonds are selected and set by hand in a mould, then secured in position by sintering in a tungsten based matrix. Allowances are made for consequential shrinkage to bring the finished dresser within specification tolerances.

Tolerance Detail

General Surface Finish Produced: 0.8uM. 32 C.L.A.

Typical Applications

• Turbine Blade

• Automobile Valves

• Crankshafts

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type 3 - CVD Sintered

THE High Performance Dresser

Our CVD sintered rotary diamond dressers have very high thermal oxidation resistance and other excellent thermal properties. CVD is perfect for secure mounting with traditional non-ferrous metal sintering. CVD sintered rotary diamond dressers can also be brazed onto a dresser body using an active braze alloy in a non-oxidizing environment.

Benefits

• Highly resistant to chipping and fracture

• Wears evenly over the dresser's entire length

• Performs regardless of dressing orientation

• Outstanding thermal stability

CVD diamond can be manufactured in a multitude of shapes, sizes, thicknesses and grades giving engineers great flexibility with this material's extreme properties. 

Dimensions

Our CVD diamond dressers can be ordered in all the standard rectangular dimensions in various lengths and square, but we also specialize in supplying non-standard custom dimensions upon request.

Typical Applications

• Metal matrix composites

• Aluminium alloys

• Glass-reinforced plastics

• Carbon fibre-based materials

• Plastics and rubbers

• Graphite

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type 4 - random set sintered

The dresser FOR QUICK DELIVERY

Random Set Sintered Dressers are most suitable where openness is required, coupled with a tight form and improved surface finish. 

Very often selected diamonds are strategically placed in the mould to support the form in vulnerable areas. The remaining area is then in-filled by centrifugal dispersion of diamonds and sintered.

Random Set Sintered Dressers have the advantage that they can be delivered quickly to meet urgent customer requirements.

Tolerance Detail

General Surface Finish Produced 0.4 uM. 16 C.L.A.

Typical Applications

• Automobile Valves

• Turbine Root Forms

• Flute Grinding

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CHOOSING THE RIGHT DRESSER TYPE

Within each of these categories there are many further variables of appropriate diamonds and setting patterns to consider when ordering dressers of this type. Specialist techniques need specialist suppliers which is why we established our Consort Precision Diamond Rotary Dresser custom product line. Since 1984, we have dedicated substantial resources to developing the finest Diamond Rotary Dressers and support services available.

At Continental Diamond Tool Limited, we focus predominately on the design, development, manufacture, install and maintenance of Rotary Diamond Dressers. And we think that gives us a unique commitment to provide our customers with the best technology can offer.

If an application calls for a Diamond Rotary Dresser, Continental Diamond Tool will provide the best tool for the job. Contact us for a free consultation and quote.

How Does CDT Guarantee Grinding Wheel Performance?

Customer satisfaction is our first priority at Continental Diamond Tool, best illustrated by our Performance Payoff Guarantee. What is that? It's our pledge to customers to guarantee a return on their investment. To summarize, if we cannot match the quality or life of your current tooling, you won’t pay a penny more than what it's worth to you. Here’s how it works:

1. Continental Diamond Tool guarantees that all of our tooling will be manufactured to the requested abrasive and dimensional specifications.

At CDT your manufacturing team will work directly with our engineers to design, test, and build tools customized to your processes in your industry. CDT will calculate the ideal abrasive size and style to meet your requirements for stock removal and surface finish while also accounting for the type of material being ground. Combine this custom grit with the best type of bond and, voilá, we have a grinding wheel design that will yield optimal performance for your operation.

Then, using state-of-the-art equipment and stringent quality control standards, we move your order into prototype and/or production to achieve some of the tightest tolerances in the industry.

2. As the customer, you define the length of time, the application requirements, and the test’s measurement for success.

With our grinding lab, we can perform remote product testing to eliminate your risk before you even have your grinding wheel in hand. Direct benefits include:

·         Accelerated product development, with no conflict between product trials and actual production time.

·         More savings and less risk, with optimization taking place during simulations rather than costly trials.

·         Advanced innovation opportunities for exploring various product types and coolant delivery methods.

·         Superior, usable data, thanks to monitoring sensors that record every aspect of each grind.

Even with simulated trials in our grinding lab, we still welcome the opportunity to put our custom superabrasive grinding wheels to the test in your live production environment. Our engineers are happy to come to your facility to aid in the setup process, compile before-and-after data, and summarize the results.

3. If we cannot match your current tooling’s quality or life, we will only charge according to its value to you, based upon the current tooling’s cost.

We would never expect our customers to settle for average or subpar performance. We believe wholeheartedly in the abilities of our team to produce superior grinding solutions for our customers. Our confidence comes from our founding principles of service, quality, dependability, and precision. However, talk is cheap, and we are a company of action. The Performance Payoff Guarantee holds us accountable to our customers. With it, you can see exactly what you are getting with your investment.

Take, for example, the experience of Jim Elliott of Advanced Carbide. After investing in a new hybrid solution for their vitrified grinding wheel, and seeing the results of their performance payoff guarantee trial, here’s what Jim had to say: “With this new bond [from CDT], we saw cycle time reductions of 20% or more, and the same amount of wear compared to our first generation vitrified wheel, which was already a vast improvement over a conventional wheel.” Click here to read more about it.

With every specialty superabrasive grinding wheel we make, we strive to improve grinding time, reduce overall tooling cost, and hit ROI out of the park.

If you have product warranty questions — or would like to request a quote — please reach out to your CDT representative, call 800-443-6629, or contact us through our online form.

What Is a Diamond Rotary Dresser?

Grinding operations often work best with some form of wheel dressing to re-establish the wheel profile and/or recondition the wheel face. Wheel conditioning typically 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. CDT engineers design each dresser to match your wheel topography so that it performs with superior strength and versatility. All are made with the highest quality CVD, natural diamond, synthetic diamond and combinations to maximize performance and roll life. Because they are custom manufactured, an abundance of configurations are possible.

Types of Diamond Rotary Dressers

There are two manufacturing methods for rotary dressers with several variations in setting/diamond application to best suit the customer application.  Below are several examples:

1. Reverse Plated Diamond Roll

Manufactured with high accuracy molds and a tightly controlled electroplating process to deposit the nickel layer.  The nickel layer holds the abrasive in place to allow for extremely complex profiles and tight tolerance work, which produce high quality surface finishes.  Because of the accuracy on the front end of the process, these rolls require little to no surface conditioning, which leave sharp natural points for superior dressing, resulting in an open grinding wheel and lower grinding forces.  Reverse plated rolls are ideal for continuous dress creep feed process, and complex forms like bearings, fuel injection, thread forms, and aerospace root forms. 

2. Sintered Diamond Roll

Using a high temperature powdered metal process to create a tough tungsten matrix to secure the abrasive in the roll.  This product is ideal for aggressive grinding and harsh working environment, while still holding tight profile tolerances and complex forms.  These are all handset products, either pattern set or random set, to allow for a wide range of options on performance, surface finish, and roll life.  Because of the manufacturing process, these rolls generally have shorter lead times and can usually be reworked to meet production demands.  Sintered rolls are ideal for simple profile rolls to complex valve grinding assemblies.

3. Sintered CVD / Disc Dresser

These dressers use the same tough tungsten matrix as the standard Sintered rolls but are unique in the abrasive they are set with and how they are typically used.  They are available using synthetic, natural, or CVD abrasive and can be set in combination to target specific performance, surface finish, and roll life.  These are typically used to traverse across the grinding wheel to generate specific profiles and wheel conditions for open and free cutting grinding of the part.  This style dresser is ideal for reconditioning, which can restore the roll to its original profile and tolerance in half the normal lead time and a fraction of the cost.

Where Can You Get a Diamond Rotary Dresser?

If you're looking to purchase a diamond rotary dresser, then you should know that Continental Diamond Tool Corporation is the final place to get them.

Experience

Since 1973, our family-owned company has built a reputation as a leading-edge manufacturer with a commitment to excellence.

Quality

Our engineers are highly specialized, and all our products are produced under stringent quality control standards.

Customization

We manufacture to your specific needs, providing you with specialized tools in a timely manner, with guaranteed satisfaction.

Precision

Our state-of-the-art equipment and expertise give our products some of the tightest tolerances in the industry.

Personalized Tech Support

From prototype to production, operations, or replacement tooling, our team works closely to get you the solutions you need.

Multiple Ways to Request an Estimate

Submit your project specifications and upload large files through our website: www.cdtusa.net/contact

Email details of your project with small file attachments to: info@cdtusa.net

Call our customer service team to talk through your project and discuss options: 800.443.6629

Why Choose Continental Diamond Tool?

There are a lot of reasons to consider Continental Diamond Tool, but the top three reasons customers choose CDT are our high level of service, quality, and consistency.

Quality is the highest priority at CDT. We’re ISO Certified, with checks and balances in place to make sure each tool is the highest quality, every time.

Consistency means repeatability, so your tool is the same from one order to the next. You don’t deviate in your usage, so we have to nail it every time, with the tightest tolerances.

CDT has made customer service a main focus. Jeff Turner, Inside Sales, says, “It’s a priority that I take very seriously. Each customer should feel like they’re our biggest one.”

If you’re wondering why CDT, reach out to us. We will follow up so you can see if we can meet your needs, including our Grinding Lab, where we can show you first hand the benefits that you can get from our tooling.

Learn more about the reasons CDT is committed to you here:

Consort Precision Diamond Featured in British Chambers of Commerce Case Study

We are pleased to share with you that Consort Precision Diamond Co Ltd has been featured in a case study by the British Chambers of Commerce. The case study has been published on the British Chambers of Commerce website and shared on their social media channels. Here is an excerpt from the article:

The Consort team is immensely proud of their geographically-diverse portfolio of customers, with the export side of their business expanding rapidly. They currently export to over 20 countries worldwide, covering Europe, USA, Canada, South America, and the Far East.

During 2019 and 2020, their international trade accounted for 51% and 63% of their turnover respectively, and 2021 figures indicate that the export side of the business will account for 70% of their revenue. Brazil, Mexico, and USA are amongst the company’s largest markets, followed by Europe.

Click here to read the full article detailing Consort's exports strategy.

In addition, Consort is proud to have been nominated regionally in the 2022 Chamber Business Awards for their exports. We would like to congratulate the award winner, Metalfacture Ltd, who has been recognized as the British Chamber of Commerce National Global Player Export Business of the Year.

Consort has also been nominated for the WCNW Chamber Business Awards in Export & International Trade. The winner for that award will be announced at the ceremony on the 11th of November.

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Consort Precision Diamond Company, a subsidiary of Continental Diamond Tool Corporation since 2018, is based in North Wales. They are a manufacturing specialist dedicated to the production of diamond rotary dressers, a complimentary product to CDT's custom diamond and CBN grinding wheels and tools.

What should you look for in a grinding wheel manufacturer?

When you’re in search of a supplier of custom manufactured grinding wheels, we know you’re going to be focused on three main components: delivery, performance, and support.

At CDT, we deliver engineered solutions to help you complete your project on time. We will also meet or exceed any requirements you have for surface finish, tolerance holding, cycle time reduction, or anything else for which you are needing engineer solutions. We also provide support throughout the duration of the entire project, from beginning to end.

“We provide information and support all along the way,” says Harrison Sheldon, Application Engineer.

Watch our video to find out more about our commitment to excellence for our customers:

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.

What is the benefit of having a grinding lab on site?

Here at CDT, we have a technologically advanced research and development grinding lab. This gives us the opportunity to work with customers to develop grinding processes that are specific to their materials, equipment, and applications. Our setup is unique, in that we’ve added numerous extra sensors to capture data on every element of the grinding process, to replicate what’s happening in the customer’s actual facilities.

We have a twofold product commitment to the Grinding Lab. One, we can develop processes for the customer and their specific application. Two, we can internally develop advanced new products that solve issues for customers before they are even known.

CDT’s customer service commitment includes the lab as well, inviting customers to reach out to us, to use our grinding lab to solve their grinding problems. Benefits to CDT customers include:

• Faster product development

• Cost savings/reduced risk

• Opportunities to innovate

• Valuable data

• Remote product testing

Read more about these benefits here or watch clips of the Grinding Lab in action, and hear more about it from Jeff Wirth, our Engineering Manager in this video:

Why Superabrasives?

When the material you are trying to process is either too hard or too delicate for conventional abrasives, custom superabrasive grinding tools might be the best solution.

What are Superabrasives?

The term “superabrasives” refers to a class of tools used in precision grinding for many industries. Superabrasive grinding products contain natural diamond, manmade diamond, and/or CBN — some of the hardest materials that can be made. Superabrasives are also sometimes called industrial diamonds: an industrial diamond is a non-gem quality small diamond that is for abrasives, cutting, and drilling tools. Other types of superabrasives include:

• Cubic boron nitride (CBN): Usually called CBN, this is the second hardest cutting tool material after a diamond.

• Polycrystalline: This is an abrasive material that has multiple collections of crystal grain structures with individual orientations.

• CVD Diamond: These are synthetic diamonds made by a process known as chemical vapor deposition. CVD diamonds grow from a hydrocarbon gas mixture. They are extremely hard and have a high thermal conductivity that is five times that of copper. They also have broadband optical transparency, are chemically inert, and only reach graphitization at very high temperatures.

• Nano-diamonds: These tiny diamonds are the product of a controlled explosion. They are sometimes called detonation nano-diamonds (DND) or an ultra-dispersed diamonds after how they are formed.

These abrasive materials have been labeled as superabrasive due to their extraordinary hardness, unparalleled performance, and longevity. Continental Diamond Tool uses these superabrasive materials to make custom grinding wheels and products, including plated, vitrified, resin bond, metal bond, hybrid bonds, and rotary dressers, for many complex applications.

Superabrasives vs. Conventional Abrasives

Superabrasives, whether natural or manmade, have a hardness range that distinguishes them as some of the most durable materials on Earth. Conventional abrasives are made with much softer abrasive materials that are less expensive but break down faster. The best abrasive product for your application depends on the material you are grinding and what properties you need to achieve your desired results.

Industries that Use Superabrasives

A great number of industries use superabrasive grinding wheels, and the custom-coated abrasives subsection of the abrasives industry continues to grow. Industries that regularly invest in superabrasive grinding wheels are:

• Aerospace

• Automotive

• Medical

• Electronics

• Composites

• Oil Industry

Advantages of Superabrasives

The advantages of superabrasive grinding wheels are more than extraordinary hardness, unparalleled performance, and longevity. These three features of superabrasives are the core of many advantages manufacturers gain by an aggregation of services that normal abrasives simply cannot deliver.

Benefits include:

• Less expensive tooling and fixturing costs

• More wheels on the spindle, smaller wheels, multiple operations

• Less floor space needed for manufacturing

• Virtual elimination of wheel wear

• Automated CNC machines, less labor intensive operations requiring less training

• Consistent surface speed from part to part

• Better overall throughput with fewer machines needed

• Improved material removal rates, lower per part abrasive costs, and higher speeds

With superabrasives, industries have been able to increase production with automated CNC equipment, compensating for a lack of available, skilled labor. With custom superabrasives that are optimized for their process, machine capabilities, and mechanization, there is less reliance on operator technique. A properly defined process, combined with automatic loaders, make for equipment that can even run itself in some cases with lights out manufacturing.

Industry Outlook

Future growth of the abrasives industries will primarily be in superabrasives. Currently, research and development of superabrasives are taking place in the following areas:

• Custom designed “hard to grind” materials in an increasing number of industries

• Creep or deep feed grinding

• High-speed, high-performance grinding of hardened steel

• Form grinding, sometimes with electroplating, in high precision, high-removal, and high-surface quality applications

• CNC-control of line grinding machines

Continental Diamond Tool stays on the forefront of new abrasive technology developments in superabrasives with our state-of-the-art grinding lab focused on research and development of new hybrid bonds that take the efficiencies of superabrasives even further.

How to select the right superabrasive

CDT has a strong group of engineers, product managers, and technical sales people who can come out to your facility to review your equipment and processes, and the parts you’re looking to grind. Or, as Troy Giacherio, Product Manager for Rotary Dressers, suggests, “you can come into our facility and we’d be more than happy to have the conversation, review the whole development process, and then make our recommendations based on what we’ve seen and communicated.” Contact us for a free quote.

Learn more about superabrasive grinding solutions in this video:

How to Order Custom Grinding Wheels

Professionals in certain manufacturing industries use grinding wheels as a normal part of their abrasive cutting, grinding, and machining processes. There are numerous types of grinding wheels, as well as assorted types of abrasive materials and grains. Having and using the right tool for the job is essential, especially for precision manufacturing. It is important to determine what you need before you place an order or get a quote.

TYPES OF GRINDING WHEELS

These are only a few examples of numerous types of grinding wheels and their uses:

• Centerless and feed wheels for creating extremely close tolerances on metal cylindrical parts, such as those for aircraft, automotive, and tool manufacturing

• Cylindrical wheels for angular, plunge, and reverse grinding

• Diamond and hybrid wheels for grinding extremely hard materials, such as carbide tips or concrete

• Dish cup wheels for cutter and jig grinding

• Mounted point wheels for deburring and profiling work on hard materials

• Straight wheels, most commonly used for centerless, cylindrical, and surface grinding on bench and pedestal grinders

• Tapered wheels for grinding gear teeth and threaded applications

TYPES OF ABRASIVES

Depending on the job you need to do and the type of grinding wheel you use, the type of abrasive you need varies. Examples of abrasives include:

• Conventional: Aluminum Oxide (corundum), Ceramic, and Silicon Carbide

• Superabrasive: Natural Diamond, Synthetic or Man Made Diamond, and Cubic Boron Nitride

At Continental Diamond Tool, we produce custom superabrasive grinding solutions. We can help you replace your conventional grinding wheel with the right superabrasive alternative.

ORDER GRINDING WHEELS

While some companies have local suppliers for their grinding wheels and abrasives, it's often more convenient to request a quote online, especially when you are looking to order custom grinding solutions. Here are the steps to take to order a custom grinding wheel:

Step 1

Determine the abrasive specifications required for the job. The proper grinding wheel is dependent on many factors including the grinder, coolant, material being ground, wheel dressing method, and more. To give you the best engineered solution for your grinding application, your supplier will need certain information to ensure you get the results you are looking for. Details you'll want to gather include:

• Type of material: carbide, ceramics, concrete or stone, glass, or metal.

• Type of grinder: manual or CNC

• Type of grinding application: OD, ID, Cylindrical, Surface, Rotary Surface, Angle Head, Double Disc, Plunge, Traverse, etc.

• Wheel diameter: varying from 0.008” to 40”

• Thickness range: varying from 0.030” to 12”

• Arbor hole size: varying from 0.040” to 20 inches

• Desired finish: extra fine, fine, medium, or coarse (for minimal to heavy removal).

• Coolant type

• Dressing method & tools

• Stock removal: If you know your selected abrasive material and required grit (varying from 20 to 8000 mesh), note that too.

Step 2

Call or use the online contact order form for your online supplier. For a custom grinding wheel, provide lots of detail about the type of tool you are using, along with its description, dimensions, and intended use. Continental Diamond Tool has a quote request form that walks you through the information we need to provide an accurate quote, and you can upload reference files if needed. Or you can always call us if you want to talk through the parameters of your project.

Step 3

At Continental Diamond Tool, we specialize in custom superabrasive grinding wheels and tools. Our team of engineers will work with you on a custom solution to your grinding needs. Depending on the nature of your project, we can run remote simulations or in-person trials and test prototypes before manufacturing the final piece. The whole process typically takes a number of weeks, but can be fast tracked if needed. At the end, our engineers will work with your team to guarantee that the grinding wheel is properly installed and performing as expected. They can also offer instruction on how to maintain your grinding wheel for ongoing high performance.

Stop getting by with a grinding wheel that isn’t optimized for the job. It's best to consult an expert to make sure your tool is a good fit for your process. In many cases, custom grinding wheels quickly pay for themselves with increased efficiency and extended tool life, and you'll see the difference to your company’s bottom line. It starts with calling 800-443-6629 or requesting a free quote online today: