Continental Diamond Tool Ltd. Earns Three Nominations for WCNW Chamber Recognition Awards

Continental DIamond Tool Limited (CDT Ltd.), the European subsidiary of Continental Diamond Tool Corporation, is excited to announce its nomination for three esteemed awards by the West Cheshire & North Wales Chamber of Commerce (WCNW Chamber). These nominations underscore CDT Ltd.'s dedication to excellence and innovation in the diamond tool industry.

The WCNW Chamber Recognition Awards celebrate businesses in the West Cheshire and North Wales region for their remarkable achievements and contributions to the local and international business landscape. CDT Ltd. is honored to be nominated in the following categories:

1. Award for Export & International Trade

This nomination acknowledges the strength of West Cheshire & North Wales exporters. Entrants must distinguish themselves on the international stage and demonstrate significant and sustained increases in export activity. CDT Ltd. takes pride in its global reach and commitment to delivering high-quality diamond tools worldwide, reinforcing its dedication to expanding its international presence.

2. Business Growth Award

Open to businesses of all sizes, this award recognizes organizations that have experienced remarkable growth in areas such as sales, profit, market share, job creation, and international trade. CDT Ltd.'s nomination underscores its unwavering commitment to growth, innovation, and excellence in all aspects of its operations.

3. Business of the Year Award

The pinnacle recognition for businesses in West Cheshire & North Wales, this award is open to companies of any size and sector. CDT Ltd. is proud to stand among other outstanding businesses, symbolizing its dedication to achieving the highest standards of performance, innovation, and corporate responsibility.

These nominations reflect the dedication and passion of the entire CDT Ltd. team. We extend our heartfelt thanks to our employees, customers, and partners for their unwavering support, which has played a pivotal role in our success.

Just last week, CDT Ltd. announced its name change from Consort Precision Diamond, aligning its identity and marketing efforts with its parent company, CDT Corporation. This strategic move comes as CDT Ltd. continues to expand its offerings in high-performance electroplated grinding technologies. You can learn more about this exciting change here.

As we eagerly await the awards ceremony in November, we express our gratitude to the WCNW Chamber for recognizing our efforts and achievements. We also extend our best wishes to all fellow nominees in these esteemed categories, as their accomplishments contribute significantly to the vibrant business community in West Cheshire and North Wales.

To discover more about the WCNW Chamber Recognition Awards and the remarkable businesses being celebrated, please visit this link. Stay tuned to our Linked In, Instagram, and Facebook pages for updates on our journey toward the awards ceremony, and join us in celebrating this momentous occasion.

At Continental Diamond Tool Limited (CDT Ltd.), we are committed to innovation, excellence, growth, and service toward our valued customers and partners worldwide. Thank you for being a part of our success story.

Consort Precision Diamond Company Announces New Identity As Continental Diamond Tool Limited

Kinmel Bay, Rhyl, U.K. (September 11, 2023) – Consort Precision Diamond Company, a top manufacturer of precision diamond tools in the United Kingdom, is pleased to share a major announcement. Effective July 10, 2023, the company has officially changed its name to Continental Diamond Tool Limited.

The new name aligns with its parent company, Continental Diamond Tool Corporation (CDT), which acquired Consort in 2018. With headquarters in New Haven, Indiana, U.S.A., CDT is recognized globally for manufacturing high-precision custom superabrasive grinding wheels, which integrates seamlessly with Consort as a distinguished and trusted producer of high-quality precision diamond rotary dressers.

At the core of this name change is a firm dedication to delivering premium quality and innovation. Over the past several years, the company has expanded its facility in Kinmel Bay to manufacture a wider range of superabrasive products and better cater to a global market. In 2021, an expansion of the Plating lab more than doubled the company’s capacity to produce the high quality tight tolerance reverse plated rotary dressers used by some of the world’s most prestigious corporations. It also paved the way for diversification into electroplated grinding wheels, which the facility began producing in early 2023.

This strategic growth is part of the company's unwavering commitment to delivering comprehensive solutions to customers. As the company continues to expand its offerings to encompass more high-performance grinding technologies in step with its parent company, aligning the name and marketing efforts of the two is a logical move. 

In the coming weeks, on-lookers can expect to see updates across various aspects of Consort's branding and materials as it transitions to Continental Diamond Tool Limited. This includes revisions to its packaging, marketing materials, website, and all pertinent documentation. The company is committed to ensuring a smooth transition, with minimal disruption to the customer experience.

“For nearly four decades, Consort has faithfully served leaders in the automotive, aerospace, and other precision manufacturing industries. We look forward to continuing our longstanding relationships with customers under our new name,” says Jeff Wirth, Managing Director of Continental Diamond Tool Limited. For further information about this transition, please send any queries to info@cdtltd.com.

About Continental Diamond Tool Limited

Continental Diamond Tool Limited is a globally recognized leader in custom precision diamond tools, specializing in all forms of precision diamond rotary dressers and electroplated grinding products. With a commitment to excellence and innovation, the company serves a diverse range of industries from its advanced manufacturing facility located in the coastal town of Kinmel Bay in Conwy County Borough, Wales, United Kingdom. Learn more at CDTLTD.com.

Understanding the Distinction Between CBN and Aluminum Oxide Abrasives

Are you ready to explore the fascinating world of abrasives? In manufacturing, we often encounter Superabrasives and Conventional abrasives. In the Superabrasives corner, we have Diamond and Cubic Boron Nitride (CBN), and their common Conventional abrasive counterparts are Silicon Carbide and Aluminum Oxide. Each serves a specific purpose. What makes CBN and Aluminum Oxide stand out is their exceptional ability to tackle those stubborn steels and metals that can't stand Carbon.

In this blog, we'll explore the properties and applications of CBN and Aluminum Oxide abrasives. Discovering their unique characteristics will help you choose the right abrasive for your specific machining needs, ensuring efficiency and top-notch results. Whether you're working with hardened steels or softer metals, the right abrasive is the key to achieving your desired outcome in grinding and machining. So, let's dive in and unlock the true potential of CBN and Aluminum Oxide abrasives.

What is CBN?

CBN is a synthetic Superabrasive known for its incredible hardness, high thermal conductivity, and thermal stability. Originally released with the trade name Borazon from GE Superabrasives, its cubic crystal lattice structure is similar to Diamond, giving it remarkable abrasive properties. With a hardness close to 10 on the Mohs scale, CBN excels in machining tough materials that require precision grinding. Its chemical composition and high thermal stability prevents chemical reactions and premature breakdown under high temperatures, when grinding ferrous metals and high-temperature alloys. What's more, because CBN doesn't react with ferrous materials, it doesn’t alter or change their properties resulting in longer life in use when ground with CBN.

CBN is a game-changer when grinding hardened ferrous alloys or super alloys that are sensitive to heat. It efficiently grinds hardened steels while maintaining accuracy and surface finish. Plus, it's a favorite for grinding ferrous metals like cast iron and stainless steel, ensuring clean and precise results without chemical alterations. CBN is a must-have tool for achieving precise and efficient outcomes in critical machining tasks.

What is Aluminum Oxide?  

Aluminum Oxide, also known as alumina, is a versatile Conventional abrasive. With high hardness and toughness, it is available in various grit sizes, making it perfect for a wide range of machining and finishing applications. Though not as hard as CBN, Aluminum Oxide is fantastic for soft metals, wood, and non-ferrous materials. While it may not match the precision of Superabrasives, it's still a reliable choice for many tasks.

In the machining industry, Aluminum Oxide is the go-to for grinding soft metals like aluminum, brass, and copper. It performs beautifully with non-ferrous materials such as bronze and titanium, without causing any chemical interactions. Its role in achieving desired surface finishes across various industries, from automotive to aerospace, is unparalleled.

Key Differences Between CBN and Aluminum Oxide Abrasives

While CBN and Aluminum Oxide both play significant roles in grinding and machining operations, they have many distinct properties that set them apart.

Crystal Structure and Hardness: CBN's crystal lattice structure is similar to Diamond, resulting in exceptional hardness and wear resistance. Aluminum Oxide, while still hard, has a lower hardness than CBN, making it more suitable for soft metals and certain alloys.

Heat Resistance and Thermal Conductivity: CBN exhibits superior heat resistance and thermal conductivity compared to Aluminum Oxide, making it perfect for grinding high hardness and heat sensitive alloys.

Material Compatibility and Reactivity: Both CBN and Aluminum Oxide are chemically inert with ferrous materials whereas Diamond and Silicon Carbide are not, thus why they are the abrasives for ferrous metals.

Cost and Practicality: CBN grain costs significantly more than Aluminum Oxide grain, resulting in higher grinding wheel prices. Because of higher hardness and better thermal conductivity, CBN wheels can provide lower grinding costs in applications where high workpiece hardness and thermal properties need to be maintained. In cases of grinding soft steels and low volume production, the lower wheel price of Aluminum Oxide makes it a more competitive option.

Safety Considerations and Handling

Whether you choose CBN, Aluminum Oxide, or another solution for your abrasive, ensuring safety during grinding and finishing processes is essential. Proper machine guarding, eye and respiratory protection, proper dust/mist extraction, and careful handling and storage of abrasives are crucial to protect workers and maintain a clean and safe work environment.

Selecting the Right Abrasive for Specific Applications

Choosing the right abrasive for your specific machining needs is vital to achieving optimal results. Making an informed decision will ensure efficient, accurate, and cost-effective grinding and finishing processes. Some factors to consider include:

Workpiece Material Characteristics: Soft metals like aluminum, brass, copper, and mild steels  may need moderate hardness abrasives like Aluminum Oxide to prevent excessive material removal, while harder materials like hardened steels and high-temperature alloys such as inconel and hardened Stainless Steel  require abrasives with superior hardness and high thermal conductivity like CBN for precise and efficient cutting and grinding.

Machining Operations and Efficiency: Superabrasives like CBN are preferred for high-precision tasks where tight tolerances and maintaining material properties are paramount, while conventional abrasives like Aluminum Oxide offer lower cost solutions for general grinding of mild steel and soft metals.

Surface Finish and Material Removal Rates: Superabrasives like CBN excel in production applications of hardened steels and Superalloys that are sensitive to heat, , while conventional abrasives like Aluminum Oxide are effective in low volume applications and for grinding of soft metals.  

Tooling and Machinery Considerations: Abrasive selection also needs to account for machinery and tooling capabilities.  The truing and dressing of Superabrasive and Conventional Abrasive grinding wheels can be different and require different tools (stationary or rotary dressers of different configurations).  Because of the difference in hardness between CBN and Alumina, Alumina being much lower, the amount of grinding debris resulting from wheel wear during grinding can be 100-300 x’s greater with the conventional wheel, which in turn needs to be disposed of.  .

Both CBN and Aluminum Oxide abrasives offer distinct advantages in grinding and machining. Considering their unique properties with specific application requirements will lead to efficient and precise processes, ensuring optimal results and safety in the workplace. And if you ever need assistance, our grinding experts at CDT are here to help. Whether it's Superabrasives or Conventional abrasives, we can help find the perfect solution for your process.

Superabrasive Grinding Technology for the Ceramic Industry

The rapid growth of ceramic and carbide components in industries such as Automotive, Aerospace, Medical, and Electronics has created new challenges for grinding professionals. The hardness, abrasiveness, and brittle nature of ceramics and carbides make them difficult to grind efficiently. Yet advancements in superabrasive grinding technology have paved the way for improved grinding processes and reduced cycle times for those that invest in new custom technology. In this article, we explore the transformative impact of custom superabrasive grinding products on the ceramics industry, highlighting the benefits they offer and the cutting-edge technologies driving these innovations.

Overcoming Grinding Challenges in the Ceramics Industry  

Ceramic and Carbide materials pose unique challenges when it comes to grinding due to their unique hardness and abrasive properties. Traditional metal bond and resin bond grinding wheels have been the go-to solution for grinding these materials. However, advancements in CNC grinding equipment and the introduction of new bond systems have revolutionized the way ceramic and carbide components are ground.

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In different industries like electronics, optics, aerospace, and advanced manufacturing, people are using carbide and ceramic coatings to make components last longer and better at handling heat. Two common ways to add these coatings are HVOF (High-Velocity Oxygen Fuel), which uses high-speed flames to spray the coating onto surfaces, and HVOC (High-Velocity Oxygen-Fuel Cold Spray), which works at lower temperatures with fast-moving gas. Another method is Chemical Vapor Deposition (CVD), where a thin layer of material is deposited on a surface through chemical reactions in the vapor phase. Using CVD or HVOF/HVOC can make components longer lasting and more wear resistant.

The inclusion of carbide or ceramic layers necessitates special consideration during the grinding process because of the inherent hardness and abrasive properties of these materials. Superabrasive grinding wheels offer superior performance in grinding these materials by reducing grinding forces, lowering power consumption, and minimizing subsurface damage. These innovative grinding products are particularly effective in reducing grinding cycle times and reducing scrap, resulting in significant cost savings and enhanced productivity.

Advances in Superabrasive Grinding Technology 

The advent of multi-axis CNC grinding with Rotary Dressers has automated grinding processes, increasing efficiency and accuracy. Spindle & High-Pressure Coolant systems have improved the delivery of coolant to critical grinding areas, optimizing swarf removal and improved the cooling and lubrication during the grinding process. High-speed grinding spindles enable a wider range of bond technology and wheel sizes to be used for ID and smaller part grinding.

New "Cutting Tool" designs, such as slotting, high porosity bonds, coolant holes, and CNC adaptors for improved rigidity, have improved tool life and performance. These designs enhance coolant flow, chip evacuation, and overall tool effectiveness, contributing to longer tool life and reduced downtime.

Innovative bond systems have been developed to address the unique challenges of grinding ceramic and carbide materials. These new bonds lower grinding forces, reduce power consumption, and lead to faster cycle times. They also minimize subsurface damage resulting in lower scrap rates while enhancing the quality and integrity of the finished components.

Superabrasive Grinding Products for Ceramic & Carbide Components

CDT's superabrasive solutions deliver significant benefits, including a reduction in grinding forces by 30% or more (compared with resin & metal bonds), reduction in cycle times by up to 50%, and significant reduction in scrap rates on these critical and costly components. These advancements help manufacturers optimize their grinding processes, increase productivity, and reduce costs.

Continental Diamond Tool (CDT), a leading provider of superabrasive solutions, offers a comprehensive range of grinding products designed specifically for the ceramics & carbide industries. Their products are compatible with major industry equipment manufacturers, including Studer, Kellenberger, Danobat, Walters, ANCA, Junker, Okuma, Koyo, USACH, Lapmaster, Peter Wolters, SpeedFam, Stahli, Supfina, and many more. CDT also offers advanced custom tool designs, such as cross cutters and hole drilling with flat bottom drills, to address specific grinding requirements. Their expertise extends to a wide range of equipment, including round tools for Anca, Haas, ITM, Normac, Rollomatic, Star, and Walters, as well as inserts for Agathon, Coborn, EWAG, Waida, and Wendt. Additionally, CDT has created surface grinders for Arter, BLOHM, Brown & Sharp, Chevalier, ELB, and Magerle, as well as Blanchard grinders for Blanchard, Bourn & Koch, and DCM.

Superabrasive grinding products have revolutionized the ceramics & carbide industry, overcoming the challenges presented by the high hardness and abrasive nature of these materials. With reduced grinding forces, faster cycle times, and reduced scrap rates, manufacturers can achieve greater efficiency, productivity, and cost savings. Continental Diamond Tool's advanced superabrasive solutions provide tailored grinding products for a wide range of equipment, enabling manufacturers to optimize their grinding processes and achieve exceptional results. As industries continue to evolve to use more ceramic & carbide materials, the use of superabrasive grinding products will undoubtedly play a crucial role in meeting the growing demand for efficient production of these components.

5 Common Questions About Industrial Diamonds For Grinding

1: What are industrial diamonds, and how are they used in grinding wheels?

Industrial diamonds can be either synthetic diamond or natural diamond and are specifically processed for industrial applications, rather than for jewelry. 

Industrial diamonds are used in grinding wheels as an abrasive that removes material from a workpiece through friction and cutting. When the grinding wheel rotates against the workpiece, the diamond particles (abrasives) efficiently remove small particles of the workpiece – resulting in geometry, size, and finish desired.

Because diamond is the hardest known material, grinding wheels with diamond abrasives are commonly used in hard material applications that require high precision and accuracy such as in the aerospace, automotive, medical and semiconductor industries. CDT has experience working with grinding operations in all of these areas.

2: How are industrial diamonds manufactured?

Natural diamonds have been used for a long time in industrial grinding. They are mined from the earth and transported to a plant for processing. Through a system that includes x-ray machines and hand sorting, the gem quality diamonds are separated from industrial diamonds. These small, lower-quality stones, otherwise known as ‘boart,’ can be used in equipment such as grinding wheels, drill bits, and dressing tools.

Synthetic industrial diamonds used in grinding wheels can be made in one of two ways: 

• High-pressure and high-temperature (HPHT) 

• Chemical vapor deposition (CVD) 

In the HPHT method, diamond-creating materials are put under high pressures and high temperatures to make it form into a diamond. In the CVD method, diamond-creating materials are put in a vacuum chamber where carbon gasses are then added to make it form into diamond. 

Whether naturally or synthetically sourced, the industrial diamonds are then crushed, milled, cut, shaped, and polished to customizable sizes and shapes. Then, the particles are bonded together to form a grinding wheel or cutting tool, typically using metal, resin, vitrified materials or electroplated in a single layer onto a metallic substrate. 

3: How do the properties of industrial diamonds affect the performance of grinding wheels?

Industrial diamonds are valued for their extreme hardness, wear resistance, and thermal conductivity. All of these impact the performance of a grinding wheel.

Extreme Hardness:

Diamonds are known for their extreme hardness because they are made up of carbon atoms that are held together in a cubic crystal lattice structure. You can think of it like a brick wall, where the precise arrangement and spacing of the bricks represents the arrangement of atoms in the cubic crystal structure. Like a brick wall, diamond is strong and stable, making it difficult to break or become deformed.

Because diamond is the hardest known material, it is not readily scratched by other materials. Instead, it does the scratching.  Because of the high strength of the carbon bonds, Diamond has the best wear properties of all abrasives unless chemically attacked by materials that react with carbon.

This gives grinding wheels the ability to precisely cut through and remove material from other hard substances like ceramics, glass and non-iron-containing metals with very precise geometries and dimensional tolerances. 

Wear Resistance:

A diamond's wear resistance refers to its ability to maintain sharp edges and cutting ability for longer, which results in longer-lasting grinding wheels that don’t need to be replaced as often.

Diamond particles can withstand high pressures generated during the grinding process – a crucial aspect of grinding that can cause other abrasive options to break down. Whereas the wear-resistant nature of a diamond abrasive maintains a durable, precise size and finish.

Thermal Conductivity:

Diamonds have the highest thermal conductivity of any known material, which is ideal for grinding due to the heat generated by the friction that occurs during the grinding process. Heat can cause abrasive particles in the wheel to become dull and less effective at cutting, as well as cause thermal damage to your workpiece.

Diamonds can conduct heat away from the grinding area more effectively than other abrasive materials. This keeps it cooler, protecting the material being ground from thermal damage and preventing the abrasive from becoming dull.

4: What are the advantages and disadvantages of using industrial diamonds in grinding wheels compared to other abrasive materials?

Advantages:

Diamond is the hardest known material due to it’s strong covalent bonds between carbon atoms and perfect crystal symmetry.  Because Diamond is harder than all other materials it is the best choice for grinding and wear resistance.  Other abrasives are softer than diamond and therefore do not last nearly as long.  Secondly, Diamond also has the best thermal conductivity and therefore removes/dissipates most effectively the heat generated during grinding.  

All of this makes diamond an advantageous choice as an abrasive because it will provide a longer-lasting durability, an improved precision, and a better quality finish.

Disadvantages:

Because of its high hardness, it also means that diamonds can’t be easily shaped or molded into different forms. Dressing of diamond wheels is done with Diamond tools, and with Diamond on Diamond, dresser life is low when compared with other abrasive types.  Secondly, Diamond grinding wheels are not recommended when grinding ferrous metals as a chemical reaction between Carbon (Diamond) and the metal is possible and results in changes of the material properties of the metal and premature wear of the Diamond grinding wheels, both of which can be detrimental.  Therefore, diamond is typically suggested for use in specialized applications for grinding of hard materials such as Ceramics, Carbides, and glasses.

5: What are the latest trends and advancements in industrial diamond technology for grinding wheels?

One of the latest trends in industrial diamonds is the increasing use of synthetic or man made diamonds. Diamonds that are grown in a lab are as real as diamonds mined from the earth. They are identical to natural diamonds in every way, except that they are created in a lab and the specific material properties of the Diamond can be tailored to specific applications..

As this process has gotten more efficient, man made diamonds can now be sourced cheaper and more readily than natural diamonds. Diamond grinding products are becoming more economically viable for a growing number of industries. CDT uses both natural and synthetic diamonds in its superabrasive products.   

Another advancement in industrial diamond grinding technology is the creation of hybrid bond grinding wheels. Hybrid wheels combine different types of bond to adhere the abrasive material, such as diamond, to the grinding wheel and achieve superior grinding performance. 

Traditionally, diamond grinding wheels use one of a handful of bonding agents to adhere the superabrasive material to the grinding wheel. Bonding options include:

• Electroplating

• Resin bond

• Metal bond

• Vitrified bond

Each of these bonding options have different characteristics which result in different pros and cons for the grinding process. You can learn more about the different bond types here. 

By combining bonds, hybrid wheels can be tailored to the needs of specific grinding applications, resulting in higher efficiency and reduced costs. CDT specializes in cutting edge, customizable hybrid bonds using diamond abrasives to provide superior results for our customers. You can learn more about our hybrid bonds here.

Industrial diamonds are a crucial component in many grinding processes, and they continue to play a vital role in the manufacturing industry. Because of their ideal thermal conductivity, wear resistance, and hardness, the technology will continue to advance to make the most use out of this favorable material. It is safe to say that industrial diamonds are not going away anytime soon, and their importance in the manufacturing industry will only continue to grow from here!

If you are wondering if diamond grinding wheels or tools would be a good fit for your specific application, contact CDT for a free quote. 

CDT Welcomes Alpex Wheel Company To The CDT Family

Continental Diamond Tool Corporation, a global leader in the manufacturing of Superabrasive grinding products, is proud to announce the newest addition to its business: Alpex Wheel Company.  Alpex Wheel Company, founded in 1954 in New Jersey, has a long-standing reputation of providing the highest quality superabrasive products and service. 

This addition brings exciting opportunities for both CDT and Alpex. CDT will benefit from Alpex's expert workforce and industry knowledge, while Alpex will now have access to CDT's extensive resources and technology, as well as CDT’s capabilities, innovations, and full array of products. 

Customers of Alpex can rest assured that CDT’s commitment to quality and service will remain. The company will continue to operate under its current management team and staff as operations transition to CDT’s global headquarters in New Haven, IN by the end of 2023.

This development is an exciting opportunity for both CDT and Alpex customers to benefit with over 100 years combined in the Superabrasive Industry, Alpex customers can expect a continuation of the highest quality Superabrasive products combined with the industry’s best customer service team.  

Continental Diamond Tool would like to thank the Baum family for their commitment to the superabrasives industry and wish them well in all future endeavors.  

CDT Expands Diamond Rotary Dresser Production

For companies in need of grinding wheel dressing, conditioning, and shaping, finding a high quality and cost effective supplier for custom dressing solutions is even easier!

Continental Diamond Tool is proud to announce that we’re expanding our capabilities to make custom Diamond Rotary Dressers (also known as Diamond Rolls) in our dressing product line.

Dressing tools are a necessary aspect of maintaining the natural wear and tear that occurs with superabrasive grinding wheels. When your abrasive becomes dull and ineffective due to particle buildup, it is recommended that you use diamond dressers to clear off the particles and make your grinding wheels perform like new again. 

While many tool and cutter grinding shops and other manufacturing facilities use stationary dressers to get that job done, more and more industries are finding uses for diamond rotary dressers — and for good reason!

As industries work with more and more advanced and complex engineering configurations, Diamond Rolls are the clear, superior choice for these applications … but why?

Simple. Diamond Rolls:

• Have precision profiles and geometry to match your specific needs

• Are designed for your specific needs, surface finish, removal rates, time savings

• Come in all shapes and sizes, from simple traverse dress rolls to complex profiles

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

CDT currently offers the following types of Diamond Rolls:

• CVD dressers

• Sintered Rotary Dressers

• Reverse Plated Rotary Dressers

Diamond Rotary Dressers are commonly used in the following industries:

• Aerospace 

• Automotive

• Biomedical

• Knives and Blades

• Bearing

Whether you are in an industry that’s looking for one of the dressing products above — or if you want to work with our engineers to develop something new— CDT is excited to serve your needs with the best possible up-and-coming technology for getting the job done right.

CDT has been in the business of providing solutions for sharpening and refinishing of superabrasive grinding wheels with Stationary Diamond Dressers since our start in 1973. In 2018, we added Diamond Rolls to our dresser line through our acquisition of Consort Precision Diamond in the U.K. who joined us with a solid reputation for making major technological advancements in rotary dresser technology. 

Now, after upgrades made in late 2022, Continental Diamond Tool has capabilities to produce many configurations of custom Diamond Rotary Dressers at our U.S. facility in New Haven, Indiana. Call us or complete our contact form for details.

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