CDT Ltd. Marks Milestone with Employee Event

CDT Ltd, formerly known as Consort Precision Diamond, is excited to mark its 40th anniversary—a remarkable milestone in the company's history. Since 1984, CDT Ltd has been at the forefront of manufacturing rotary diamond dressers, playing a crucial role in industries like aerospace and automotive. This journey of four decades has been driven by innovation, precision, and an unwavering commitment to excellence.

As we celebrate this significant anniversary, we acknowledge that our success wouldn't have been possible without our dedicated employees. To show our appreciation, we've invited Pizza Llan, a local pizza van, to join us at our premises. It's a small token of our gratitude to the team whose hard work and dedication have made our achievements possible. Here's to 40 years of success—and many more to come!

Members of the leadership team at Continental DIamond Tool Ltd. present employees with a 40th anniversary cake. (From left) General Manager Troy Giacherio, Finance Manager Michaela Lawton, Production Manager Justin Hughes, and Managing Director Jeff Wirth.

Managing Director Jeff Wirth visits from CDT’s U.S. headquarters for the occasion.

Jeff expresses gratitude to employees for their commitment to the company, emphasizing a vision for the future and its continued success.

Recent retirees came back to celebrate the company’s 40th anniversary, marking four decades of legacy and achievement.

Employees enjoy Pizza Llan, a local pizza van, as part of the festivities.

Nothing says 'thank you' like a plate of pizza.

Who’s ready to dig in?

Smiles with every slice.

Former colleagues reunite, sharing memories and catching up on old times.

Celebrating 40 years of excellence: 1984-2024

CDT Ltd. Engineers Adopt Much-loved Hospice to Help Final Wishes Come True

Kinmel Bay-based engineering company Continental Diamond Tool Ltd have made a £1,000 donation to St Kentigern Hospice in St Asaph and pictured are, from left, Becky McNay, Advanced Nurse Practitioner; Helen Turberville and Michaela Lawton of CDT with Alwyn Mason, corporate fund raiser at St Kentigern Hospice.

A much-loved North Wales hospice has been adopted as a favored charity by Continental Diamond Tool Ltd (CDT) after staff voted overwhelmingly to support it.

St Kentigern Hospice, which serves Denbighshire, eastern Conwy and western Flintshire, was chosen by CDT because of the “wonderful care” it has shown for relatives of team members, including both parents of engraver and dispatch officer Helen Turberville.

The company,  which supplies sophisticated parts for production machinery for Rolls-Royce and other aerospace companies, has made its first donation to the charity with Helen handing over a cheque for £1,000 at the hospice in St Asaph. CDT employees encourage others to join them in supporting this worthwhile cause. You can make a donation here.

Their donation was made to mark the 40th anniversary of this CDT location – one of only two of its kind in the UK that specializes in precision diamond grinding products -  which employs 40 skilled staff at its factory on the Tir Llwyd Industrial Estate in Kinmel Bay.

Helen said: “My parents, Maureen and Ted Felton, from Kinmel Bay, were both here and the care and support the hospice gave was a great comfort to them and to us as a family.

“My mum used to come to the day centre here and made many things I still have at home including a tie-dyed silk scarf.

“Then she was a resident here and was struggling with her mobility and they helped her a lot before she passed away here.

“My dad was in hospital in Liverpool and I asked for him to be moved to Ysbyty Glan Clwyd and they said he only had a matter of days so I requested that he come to St Kentigernand the staff here managed to get him in.

“He knew we were trying to get him here because on one of his good days we managed to tell him and it meant a lot to all of us as a family.

“St Kentigern is a wonderful place and my mum made a lot of friends here. It’s very comforting here and I’m delighted that CDT are supporting it.”

The hospice has been extended to 12 beds from eight but it also provides extensive day care and respite services as well as wide range of therapies and over the past 12 months more than  600 people from across the area have used its services.

They cost £3.6 million a year with three-quarters of that raised by St Kentigern team, of fundraisers who are currently working on one of the year’s major events, the Twilight Trek which takes place on Saturday, June 29.

They also provide a Wish Ambulance which aims to make the final wishes of its residents come true and they have included a lady in her 30s who wanted to spend a final couple of hours in her own home.

Another patient wanted to see a fireworks display for the last time and the Royal National Lifeboat Institute came in to stage a show

CDT are now partnering with St Kentigern to support the hospice and make those dreams come true. You can extend your support, too, by making a donation here.

CDT Finance Manager Michaela Lawton said: “It is a fantastic cause, it’s local and after a discussion with our employees about which charities to support St Kentigern was put forward and it was a no-brainer really.

“I came to visit the hospice and was so impressed by the work they are doing and by the fantastic range of services and activities they provide, not only to their patients but to their families at the most difficult time in their lives.

“This is the 40th anniversary of the company and we want to set up a long-term partnership with St Kentigern to mark that and we aim to support them with regular donations in the future.”

Advanced Nurse Practitioner Becky McNay, from Wrexham, joined St Kentigern four years ago and she said: “It’s been amazing. I’ve really loved it. It’s such a rewarding place to work.

“You can’t just come here to a place like this because it’s a job. You have to really want to do it and it’s really great to build relationships with the patients and with their families because they play such an important role.

“I had always wanted to do palliative care from when I was 16 when my nan came to live with us and she was terminally ill.

“Here’s it’s not just about the process of dying. There’s much more to it than that with respite care and outpatients services and the complementary therapies we offer like massages and a wellbeing programme which covers a different topic each week.

“There’s also now advanced care planning because if someone is diagnosed with a life-limiting illness it’s important to have advice on wills and legal matters and of course it is very rewarding if you can be there for someone emotionally as well.

“I really enjoy the one to one care and the privilege of having time to second with patients and their families – you just wouldn’t get the same amount of time in an acute ward of a hospital.”

The precision manufacturing company was founded in 1984 as Consort Precision Diamond and in 2018 was bought and rebranded by Continental Diamond Tool, based in New Haven, Indiana.

It makes a range of highly specialised diamond dressers and grinding tools for advanced manufacturing industries, including the aerospace, automotive, medical and semi-conductor sectors.

More than 60 per cent of the company’s products are exported to 30 countries, with sales growing particularly strongly across Europe and Asia, as well as North America.

Related Links:

https://stkentigernhospice.org.uk/

https://www.wales247.co.uk/big-hearted-engineers-adopt-much-loved-hospice-to-help-final-wishes-come-true

https://www.rhyljournal.co.uk/news/24270609.kinmel-bay-engineers-adopt-st-asaph-hospice-help-wishes-come-true/

https://www.baysideradio.co.uk/news/big-hearted-firm-adopts-much-loved-local-hospice-8842

Meet The Team Behind CDT's High Performance Resin Bond Products

Behind every exceptional product is a dedicated team committed to excellence. At CDT, this is exemplified by our Resin Bond department, where talented individuals collaborate to create high-performance Resin Bond CBN and Diamond tools tailored to meet the unique needs of customers. This video and article tell the story of our remarkable team and their dedication to crafting superior products.

The Ingredients for Success in manufacturing Custom RESIN BOND Grinding Wheels

An Experienced Team

Since its launch in 1978, the Resin Bond product line has been a cornerstone of CDT's success, constituting a sizable market and just over 18% of CDT’s outgoing sales in 2023. With 40 years of experience in the industry, Resin Bond Product Line Manager Jim Fell proudly states, "We can tailor a product to anything that the customer needs, any type of specification that they need, and any type of application." 

Having worked at Continental Diamond Tool for more than two decades, Resin Bond Pressing Lead Nick Rorick embodies the spirit of craftsmanship and dedication that has put CDT Resin Bond CBN and Diamond Grinding Wheels on the map. In his video interview, Rorick emphasizes, "What sets us apart is the team we have behind our products here at CDT. They put their heart into every tool they make."

Customer Focus

At CDT, customer satisfaction is our top priority. Jackson Birkenbeul, a Resin Bond Design Engineer, emphasizes the importance of addressing customer needs promptly and precisely. In the video, he remarks, "Our focus is not just on manufacturing products but on solving customer challenges." This dedication to understanding and meeting customer requirements underscores CDT's commitment to excellence and service.

Innovative Process

Using a combination of phenolic resin and CBN or Diamond superabrasive, our Resin Bond engineering and production team can design and manufacture thousands of product combinations. The production process begins with formulating a recipe that is tailored to the customer's specific application. A unique blend of bond material, abrasive, and fillers are purposefully selected to optimize grinding performance. 

The custom formulation undergoes meticulous mixing in specialized tumblers before being poured and packed into mold cavities. Then, molds undergo hot pressing, where precise control over temperature and pressure ensures the creation of grinding wheels with the desired density. Finally, the wheels proceed to finishing, where they are machined and ground to achieve the intended size and geometry, allowing our Resin Bond products to be tailored to any specification required.

A Multitude of Applications

"Anything that can be cut, ground, polished, or sharpened, we can do," says Kyle Hockemeyer, CDT Pressing Tech. "In precision grinding, the consistency and repeatability of our product is one of our main goals. We strive to get a repeatable process that can be done on a regular basis to have quality, consistency, and delivery in a timely fashion."

Inside the Resin Bond department, 20+ employees work hard to make sure every order meets CDT's high standards for quality and performance. With the addition of a third shift in 2021 and an expansion in 2024 to accommodate new technology and machinery, this product line continues to grow in step with customer demand.

Putting it all together

The Resin Bond team at CDT epitomizes craftsmanship, innovation, and dedication. Their relentless pursuit of excellence and deep-seated commitment to customer satisfaction set them apart in the competitive landscape of precision grinding wheel manufacturing. As our team continues to innovate and push boundaries, customers can trust that CDT's Resin Bond products represent the pinnacle of quality, performance, and reliability.

Conventional Abrasives vs. Superabrasives

In Episode 4 of The Grinding Chronicles, Continental Diamond Tool Engineering Consultant Jon VanSant investigates  the history of common abrasive materials and their key differentiating characteristics that impact wheel life, cutting performance, and efficiency. Using the wrong abrasive for your application can significantly increase your cost per part. Watch Jon’s video or read the article below to learn the differences between conventional abrasives and superabrasives.

The Grinding Chronicles - Episode 4

Understanding Abrasive Evolution

In the early 1800s, precision grinding relied on naturally occurring abrasives like emery. Fast forward to the late 19th century, and we witnessed pivotal developments with the advent of "Carborundum" or silicon-carbide by Dr. Edward Acheson in 1891, followed by the patenting of 'Alundum' or aluminum oxide by Aldus Higgins in 1904. The landscape changed once again with the introduction of synthetic diamond in 1954 and cubic boron nitride (cBN) in 1957, marking the emergence of superabrasives. Although superabrasives were first synthesized in the 1950’s, it took two decades before commercial products became available.

Distinguishing Characteristics

To understand the difference between conventional abrasives and superabrasives, let’s examine three key characteristics: hardness, thermal conductivity, and friability.

• Hardness: An important consideration in abrasive selection, superabrasives like cBN and Diamond demonstrate superior hardness compared to Aluminum Oxide and Silicon Carbide. This is part of what makes superabrasives super, and makes them particularly efficient when grinding extremely hard materials.

• Thermal Conductivity: Enhanced thermal conductivity facilitates efficient heat transfer during grinding operations, ensuring minimal damage to the workpiece. This is critical where surface finish is concerned.

• Friability: Friability reflects the fracture or impact toughness of an abrasive and underscores another crucial aspect. Analysis reveal a substantial disparity between conventional and superabrasives, with the latter exhibiting remarkable compression fracture strength. When comparing the compression fracture strength of diamond and aluminum oxide at a particle size of 400 microns, there is a 10:1 difference between the conventional abrasive and the superabrasive.

Performance Metrics

Moving beyond physical attributes, an examination of performance metrics such as cut, wear, and dressing efficiency further demonstrates superabrasives prowess. 

• Cutting Efficiency: Superabrasives like Diamond and cBN require less power and force for cutting operations, ensuring efficient material removal. 

• Wear Resistance: Superabrasives demonstrate significantly higher wear resistance, leading to prolonged wheel life and reduced downtime when compared to conventional abrasives.

• Dressing Efficiency: Superabrasives also excel when considering downtime for dressing since they maintain dressing efficiency over extended periods. In some cases, we have seen up to 20 times the parts per dress. With less frequent dressing comes more consistent performance. Plus, you’re only taking off a tenth of the material in dressing, so your wheel lasts much longer. 

Cost Considerations

Superabrasives, with their many advantages, do come with a substantial up-front investment. Even so, many companies see sustainable returns.  

• Long-Term Value: Superabrasives offer enhanced productivity and cost-effectiveness that often results in lower cost per part over time.

• Application Considerations: Recognizing that not every application warrants a superabrasive grinding wheel, factors such as machine tools, fluid compatibility, and work volume must be considered. Superabrasives are most cost effective in high volume, extremely demanding applications. 

Expert Guidance

Thank you for joining us on this exploration of grinding wheel abrasives. If you would like help deciding which abrasive would work best to optimize your grinding process, don't hesitate to reach out to our engineering team at TheGrindingChronicles@CDTUSA.net. Until next time, check out additional insights and discoveries on other episodes of The Grinding Chronicles.

Streamlined Finishing and Shipping of Precision Grinding Wheels

From aerospace components to medical devices, industries rely on a reliable supply of finely tuned machinery and tooling to achieve optimal, cost effective results. At the heart of many precision machining operations lie custom CBN and Diamond grinding wheels, meticulously crafted to exact specifications. However, the journey from concept to completion involves more than just production. It ends with two critical stages — finishing and shipping —which ensure that these essential tools reach their destinations in prime condition. This article looks at the intricacies of these processes.

Precision in Finishing

Finishing is the bridge between production and the end-user, where the grinding wheels undergo meticulous inspection and refinement. Each custom wheel is subjected to rigorous quality control measures at this final stage, along with incremental checks earlier in the production process, to ensure it meets the stringent standards set forth by the industry and the customer.

Balancing & Surface Enhancement

Surface finish plays a pivotal role in the performance of grinding wheels. Through a combination of advanced and timeless techniques in polishing, the surface is refined to minimize friction and maximize efficiency during operation. Whatever the particular grit size, bond type, or configuration, this step ensures that the wheel’s customization aligns perfectly with its intended use. 

It is at this stage that our Finishing Department balances the grinding wheel, making minor modifications as needed. Balancing ensures that our tools produce high quality parts for the customer with reduced scrap, less vibration, and less wear on the spindle and machine.

"The key to working in the Finishing Department is to be a hard worker, detail-oriented, and someone who takes pride in their work," says Tony Police, CDT Finishing Tech. “In this department, we clean and polish tools to get them ready for the quality department to check and ship.”

Inspection and Quality Assurance

At CDT, every order ends with a comprehensive inspection of each grinding wheel. Highly trained technicians meticulously examine every aspect, from dimensional accuracy to surface finish, verifying that it aligns precisely with the specifications dictated by the engineer. Any deviations are promptly addressed to maintain the highest levels of precision for diamond grinding wheels.

“In the quality department, we use advanced technology to compare the tools to the print, make sure they are to spec, and exactly what the application requires,” says CDT Quality Tech Leslie Gurzynski. “At CDT, we regularly invest in new processes to ensure the best results for our customers.”

Customization and Labeling

At this final stage, the grinding wheel is either white labeled or engraved with the CDT logo. Additional labeling with essential information such as part numbers and usage instructions facilitates seamless integration into the customer’s workflow.

Efficient Shipping Solutions

With the finishing touches complete, the focus shifts to the final stage of the process – shipping. Timely and secure delivery is crucial to minimize downtime and keep operations running smoothly. Leveraging efficient shipping solutions ensures that custom precision grinding wheels reach their destination promptly and intact.

Packaging

Proper packaging is crucial to safeguarding the integrity of the grinding wheel during transit. Specialized packaging materials and techniques are employed to minimize vibration and impact, reducing the risk of damage en route. Each wheel is securely encased to withstand the rigors of transportation, providing peace of mind to both the manufacturer and the end-user. Product safety information is accessible through a QR code printed on the packaging. Dressing sticks for wheel maintenance are also routinely included when appropriate for the convenience of our customers.

Logistics Optimization

Efficient logistics management is essential to streamline the shipping process. Leveraging advanced tracking systems and strategic partnerships with reliable carriers, Continental Diamond Tool can ensure timely delivery while optimizing costs. Each month, CDT ships out more than 1,600 boxes of custom products. From domestic shipments to international exports, meticulous planning and coordination ensure that custom grinding wheels reach global destinations efficiently.

"Maximizing quality and efficiency for our customers is our primary goal," says Brad Miller, Shipping Manager at CDT. "With our move into the new building six years ago, and with each expansion, we've created more space to work and a better flow of tooling through final inspection and out the shipping doors." 

Customer Support

A commitment to customer satisfaction extends through production, shipping, and beyond. Dedicated technical support teams stand ready to address any inquiries or concerns throughout the shipping process. From tracking updates to post-delivery assistance, proactive communication fosters trust and reinforces our dedication to excellence.

“If a customer faces challenges installing or adjusting the settings for a new grinding wheel, that's where our expertise comes into play,” says Blu Conrad, CDT Application Engineer. “Our application engineers don't just offer remote support; we go the extra mile by personally visiting customers' locations when needed to fine-tune their operations onsite, ensuring optimal performance and satisfaction.”

In conclusion, the finishing and shipping of custom precision grinding wheels are integral components of the manufacturing process. By upholding uncompromising standards of quality and efficiency, Continental Diamond Tool can ensure that these essential tools meet the exacting demands of modern industry. From concept to the production floor, precision drives innovation and excellence every step of the way.

To request a quote or place an order for a custom precision grinding product, please call 800-443-6629 or submit your project specifications using our website’s contact form.

Students Build Careers in Engineering with CDT Apprenticeships

(From left to right) Rhys Butler, left, and Corey Jones who are building careers in engineering with the apprenticeship programme at Continental Diamond Tool Ltd. in collaboration with Coleg Llandrillo in North Wales.

An 18-year-old sixth form student is getting a taste of the world of precision engineering after being inspired by the success of a high flying company.

Rhys Butler, a pupil at Ysgol Glan Clwyd in St Asaph, is now on an eight-week work experience programme after writing to Continental Diamond Tool, on the Tir Llwyd Industrial Estate in Kinmel Bay, which is withing walking distance of his home.

According to Rhys, he was prompted to get in touch when he read a news story about the firm which supplies sophisticated parts for production machinery for Rolls-Royce and other aerospace companies in the UK.

Continental Diamond Tool Ltd. (CDT), which employs 40 skilled staff and is celebrating its 40th anniversary this year, is one of only two companies of its kind in the UK.

It makes a range of highly specialised diamond tools for advanced manufacturing industries, including the aerospace, automotive, medical and semi-conductor sectors.

Rhys said: “I saw the story about the company being under new American ownership and I was looking for work experience for my CV so I emailed in an application and they came back to me straight away.

“They’ve given an eight-week programme so I go in one day a week and I’m going through the different processes they do and they show me and explain how they work.

“One Wednesday I was actually working on putting the diamonds into the tooling. It’s been a brilliant opportunity.

“I’ve always been interested in cars and how machines work and I’m doing engineering in sixth form and go to the Llandrillo College campus in Rhyl every Thursday which is really helpful.”

Rhys often works alongside Corey Jones, 19, also from Kinmel Bay, now in his second year as an apprentice who also took the work experience route to a place with CDT.

He said: “I did my A-levels at Eirias High School in Colwyn Bay and then did Level Three Engineering at Coleg Llandrillo’s site at Rhyl with work experience here and they offered me an apprenticeship.

Apprentices get to experience hands-on learning and use their engineering skills in real world applications.

“They wanted me to get used to what’s involved so I worked here through my summer holidays and started my apprenticeship in September in Level Four Engineering.

“I knew there was a lot of maths in engineering and I’d always enjoyed that and I like to challenge myself by learning about the different machines so I’m really enjoying it.

“I had tried a few places for work experience and Coleg Llandrillo suggested here and it’s been brilliant.

“The people here are really great and very knowledgeable with lots of experience you can learn from – I work with someone who has experience on every machine and he’s a big help.

“We’re working for businesses like Rolls-Royce which is fantastic so I want to do the best I can and really build a career here.”

Michaela Lawton, CDT Finance Manager, said: “We have been running an apprenticeship scheme here for a long time and historically it’s been successful and two of our apprentices who moved on after a few years have actually come back to us.

“We have a very good relationship with Coleg Llandrillo and it really helps that they have a campus at Rhyl with a strong and well-equipped engineering department.

“What we do here is so unique and so niche that we expect our apprentices to learn the core skills in college to give them the platform to build on with the highly specialised work we do here.”

CDT has been boosted by a £1.6million investment by their American owners and has opened a second production unit on the Tir Llwyd Estate to house its new electro-plating operation which has received support from Welsh Government.

More than 60 per cent of the company’s products are exported to 30 countries, with sales growing particularly strongly across Europe and Asia, as well as North America.

The company, which celebrates its 40th anniversary this year, was founded originally as Consort Precision Diamond and in 2018 was bought and rebranded by Continental Diamond Tool Corporation, based in New Haven, Indiana.

Related Links:

Coleg Llandrillo

https://www.rhyljournal.co.uk/news/24143441.st-asaph-pupil-gets-gem-chance-high-flying-kinmel-bay-firm/

https://www.denbighshirefreepress.co.uk/news/24143441.st-asaph-pupil-gets-gem-chance-high-flying-kinmel-bay-firm/

https://bnnbreaking.com/world/uk/from-classroom-to-cutting-edge-a-local-students-journey-into-aerospace-engineering

https://www.gllm.ac.uk/news/rhys-and-corey-shine-with-diamond-tool-firm

Images captured by Mandy Jones Photography.

Coolant Application Techniques to Reduce Wheel Wear and Burn in Grinding

In Episode 3 of The Grinding Chronicles, Continental Diamond Tool Application Engineer Blu Conrad explains some essential aspects of coolant application that can impact your grinding performance. By having the correct placement of coolant lines and optimizing your coolant setup, you can significantly reduce cycle times, minimize wheel wear, and prevent burning during the grinding process. Watch Blu’s video or read the article below to learn how.

The Grinding Chronicles - Episode 3

Coolant Application and Its Impact on Grinding Performance

Most grinding operators know that reducing heat generation in grinding is crucial for avoiding excessive wheel wear and burn. However, you might not be aware of the various strategies available for achieving this goal. In this article, we will explore how coolant application can mitigate these factors.  It starts with four key considerations in cooling: Velocity, Flow, Line Placement, and Temperature.

Velocity Matters

One critical factor in effective coolant application is ensuring that the coolant is spraying at the correct velocity, typically ranging between 70% and 100% of your grinding wheel speed. This velocity is essential because of a force called the air barrier. 

As a grinding wheel rotates, it creates an air barrier around its perimeter. To penetrate this barrier and deliver coolant to the grinding zone, the coolant stream must travel at the appropriate velocity. If it is too slow, the grinding wheel can blow the coolant away. Conversely, if the velocity is too high, the coolant may make contact with the grinding wheel and bounce off, rendering it ineffective in reaching the desired area.

Balancing Flow Rate

In addition to velocity, the amount of coolant flowing from the coolant line, known as the Flow Rate, is equally crucial. Flow rate and velocity are interrelated, and their optimization is a balancing act. 

In grinding, you often have a choice between low-pressure, high-flow setups, or high-pressure, low-flow configurations. If the flow rate is too low, there won't be enough coolant to adequately cool the grinding process, potentially leading to overheating and damage. Conversely, if the flow rate is excessively high, you will be wasting coolant, resulting in inefficiency and increased operational costs.

Utilizing Nozzles for Optimization

A practical approach to achieving the ideal Velocity and Flow is by using nozzles. While standard jet nozzles are suitable for many grinding applications, different grinding processes may require wheels with distinct shapes, such as flat or radial profiles.

In such cases, it is often more effective to employ nozzles and coolant lines that have been specifically engineered, designed, and tuned to accommodate these unique wheel types. This ensures that the coolant is delivered with the appropriate velocity, flow, and, equally importantly, in the correct position.

Positioning and Direction

The position and direction of the coolant are critical factors in coolant application efficiency. Ideally, you want your coolant jet to spray just before the point of contact, where the grinding wheel and workpiece meet. Additionally, the coolant should flow in the same direction as the rotation of the grinding wheel.

If the coolant stream strikes too far above or behind the point of grinding contact, it will fail to effectively enter the grinding zone, missing the opportunity to cool the process where it is needed most.

Achieving Efficiency in Your Grinding Process

Optimizing coolant applications is a fundamental aspect of enhancing the efficiency and performance of your grinding processes. By carefully considering Velocity, Flow, Line Placement, and Temperature, you can significantly improve cycle times, reduce wheel wear, and prevent burning during grinding operations.

At Continental Diamond Tool, we understand the importance of precision coolant applications and many other factors in achieving superior results. Whether you require standard jet nozzles or specialized coolant solutions tailored to your specific needs, we have the expertise and technology to help you isolate those parameters that are holding back your grinding performance.

To explore our range of grinding solutions and learn more about how we can assist you in achieving exceptional cycle times and wheel life, email us at TheGrindingChronicles@cdtusa.net. Our engineers welcome the opportunity to meet your most challenging tooling requirements.

Part Masking of Plated Grinding Wheels

Part masking is a crucial technique employed in the plating process for CBN (Cubic Boron Nitride) and diamond grinding wheels. This method involves selectively covering specific areas of a metal substrate before plating to protect them from the plating solution. Part masking plays a significant role in ensuring the precision, quality, and functionality of grinding wheels used in various industries, from manufacturing to automotive and aerospace. In this article, we will delve into what part masking is, how it is done, why it is essential in the plating process, and what it takes to excel at this intricate skill.

What is Part Masking?

Part masking is the process of shielding specific areas or features of a substrate to prevent them from being plated during the plating process. It is achieved by applying a masking material to the surface of the substrate in a controlled and precise manner. The masking material can be in the form of tapes, paints, or other coatings that can resist the heat and duration of time in the plating process.

How is Part Masking Done?

The process of part masking involves several steps:

1. Surface Preparation

   Before masking, the metal substrate is thoroughly cleaned and prepared. This step ensures that the surface is free from contaminants, oils, coolants, machining residues and oxides, which can interfere with the adhesion of the masking material.

2. Masking Material Selection

   The choice of masking material depends on factors such as the type of substrate being plated, the plating process used, and the specific areas that need protection. Common masking materials include specialized masking tapes, latex, and resin-based coatings. Continental Diamond Tool employs all of these methods in its process.

3. Application of Masking Material

   The masking material is applied precisely to cover the areas that should not be plated. This can be done manually or using brushes, stencils, scribes or automated equipment. For more complex patterns, careful attention is given to ensure that there are no gaps or leaks in the masking material.

4. Cure or Drying

   Depending on the type of masking material used, it may need to be cured or allowed to dry thoroughly. This step generally takes a specific amount of time and ensures that the masking material remains intact and impermeable during the plating process.

5. Plating

   Once the wheel has been masked and cured, the substrate is immersed in the plating bath, where the exposed areas are plated with the desired abrasive material, such as diamond or CBN particles. The masked areas remain untouched, preserving their original characteristics.

6. Mask Removal

   After the plating process is complete, the masking material is carefully removed, revealing the plated surface underneath. This can be done through various methods, such as peeling off tapes or dissolving the masking material with solvents.

Why is Part Masking Essential?

Part masking serves several crucial purposes in the plating process for diamond and CBN grinding wheels:

• Precision and Quality

  Part masking ensures that the plating is applied precisely to the intended areas, maintaining the tight tolerances, quality, and accuracy essential to precision grinding.

• Functionality and Performance

  By protecting specific features of the grinding wheel, such as arbor holes, flanges or threaded holes, from plating, part masking helps maintain their functionality and performance, ensuring they are dimensionally fit and operate correctly.

• Cost Efficiency

  Masking reduces the amount of plating material used, minimizing waste and lowering production costs. It also prevents the need for costly post-plating rework to remove unwanted plating.

• Customization

  Part masking, applied by hand, is customizable. This allows manufacturers to create tailored, complex products to meet specific customer requirements.

What It Takes to Be Good at Part Masking

Part masking is a specialized skill that requires attention to detail, precision, and an understanding of materials and processes. Here are some key attributes and considerations for those looking to excel in this field:

Attention to Detail

Successful metal part maskers must have a keen eye for detail. Precision is paramount in this process, as even the smallest imperfections or gaps in the masking material can lead to plating errors.

Material Knowledge

Familiarity with various masking materials and their properties is essential. Different materials may be required for specific applications, and understanding their characteristics can ensure the right choice is made.

Patience and Dexterity

The application of masking material can be a delicate and time-consuming task. Patience and manual dexterity are necessary to achieve consistent and high-quality results.

Problem-Solving Skills

Maskers may encounter challenges such as complex shapes or irregular surfaces that require creative problem-solving to ensure proper masking.

Adherence to Safety Protocols

Safety is paramount when working with masking materials and plating chemicals. Understanding and following safety protocols are crucial to prevent accidents and exposure to hazardous substances.

At CDT, our masking department has almost 50 years of combined experience in this highly specialized field. The superior quality and stellar reputation of our plated products are a testament to their expertise.

If you are passionate about precision craftsmanship and believe you have the skills and attributes required for part masking, we encourage you to consider career opportunities in this field. At Continental Diamond Tool, we value skilled professionals who can contribute to our commitment to excellence.

To explore potential positions and apply for a rewarding career in electroplating or other positions in our industry, visit our careers page.

How to Order a Custom Electroplated Grinding Wheel

At CDT, we take pride in the excellence of our masking and plating departments. Part masking is an indispensable technique in the production of plated diamond and CBN grinding wheels to ensure the delivery of the very best products. It requires a unique set of skills, including attention to detail, material knowledge, patience, and problem-solving abilities. Those who excel in this field play a vital role in providing the precision, quality, and functionality of grinding wheels used across various industries.

If you are interested in ordering a custom plated grinding wheel or have any inquiries, please don't hesitate to contact our customer service department. Our team can connect you with our experienced plating engineers to start the process today.

Advantages of Using Electroplated Diamond Grinding Wheels for Precision Grinding

With precision machining and grinding, the selection of tools plays a pivotal role in determining efficiency, profitability, and overall success. Among the many options available, electroplated diamond and CBN (cubic boron nitride) wheels rank high as indispensable assets for many manufacturers worldwide. These tools offer a unique combination of advantages that contribute significantly to superior performance and cost-effectiveness. In this article, we explore four key reasons why these tools are at the forefront of precision machining and grinding.

1. Consistent Distribution of Abrasive Particles

In precision grinding, the even distribution of abrasive particles is often critical for consistency. Electroplated diamond grinding wheels excel in this aspect, ensuring a uniform dispersion of abrasive particles across their entire surface. Unlike alternative bonding methods that may result in irregular spacing of abrasive grains, electroplated tools embed diamond particles evenly in a single layer. This uniformity translates to predictably consistent grinding or cutting performance. The same is true for electroplated cbn grinding wheels.

In practical terms, this means achieving precision and accuracy in your workpiece everytime, pass after pass. Whether working with robust metals, fragile ceramics, or intricate composites, manufacturers can place their trust in electroplated grinding tools to deliver a reliable and uniform cutting or grinding action.

2. Strong Bond Between Abrasive and Substrate

Another distinguishing factor that sets electroplated diamond tools apart is the robust bond formed between the abrasive particles and the tool's substrate. During the electroplating process, diamond grains become firmly embedded within a nickel or other metallic matrix, creating a tool of exceptional durability and resilience.

This sturdy bond ensures that the diamond particles remain securely attached to the tool's surface, even when subjected to high-speed or high-pressure operations. Consequently, these tools maintain their sharpness and cutting efficiency over an extended period, eliminating the need for dressing and maximizing time between replacements. This durability translates into significant cost savings by reducing downtime and material wastage.

3. Free Cutting Action Equates to Fast Cycle Times

Electroplated diamond tools offer a "free cutting action" that speeds up the grinding and cutting process significantly. Unlike conventional tools that may generate excess heat, clog, or wear unevenly, electroplated diamond tools efficiently remove material with minimal resistance.

This means reduced cycle times for manufacturers. Jobs that used to take longer can now be completed faster and with more precision. Whether shaping aerospace components or fine-tuning medical devices, electroplated diamond tools deliver both speed and accuracy. Fast cycle times translate to increased throughput, shorter lead times, and enhanced competitiveness in today's manufacturing landscape.

4. Maintenance and Reconditioning: The Strip and Replate Program

At Continental Diamond Tool (CDT), we go above and beyond to extend the lifespan of electroplated grinding wheels through our innovative Strip and Replate Program. This program harnesses strip technology to safely remove worn-down abrasives without compromising the wheel's core. We employ a chemical solution to delicately eliminate old abrasives, preserving the integrity of the wheel's substrate. After stripping, a new layer of abrasive material is expertly applied through electroplating.

The outcome? A rejuvenated electroplated grinding wheel that performs at its best. These reconditioned wheels undergo rebalancing to ensure optimal performance during extended runs. This program not only maximizes tool lifespan but also minimizes waste, translating into cost savings and reduced downtime.

How Electroplated Grinding Wheels Yield Long-Term Cost Savings

At CDT, our electroplated grinding wheels are engineered to endure heavy usage, consistently deliver high performance, and enjoy an extra-long wheel life compared to other wheel types. This durability translates into substantial long-term cost savings — as much as 40% in some instances. Plus, the "free cutting action" of electroplated diamond tools is a powerful ally for manufacturers seeking faster cycle times without compromising quality. These tools optimize efficiency, boost productivity, and meet the precise demands of modern machining and grinding processes. 

Industries Benefiting from Electroplated Grinding Tools

A wide array of industries benefit from the unique advantages that diamond plated tools offer. Here's a glimpse into some of the key sectors where these tools play a pivotal role:

Aerospace: In the aerospace industry, precision and quality are paramount. Diamond plated tools shape and finish critical components like turbine blades, engine parts, and aircraft structural elements. They deliver the precision required to ensure the safety and reliability of aircraft.

Automotive: The automotive industry relies on diamond plated tools for tasks such as sharpening cutting tools, honing engine components, and producing high-precision parts. These tools contribute to the efficiency and durability of automotive systems.

Medical Devices: The production of intricate and high-precision medical devices, including surgical instruments and implants, relies on diamond plated tools. They enable the manufacturing of components with tight tolerances and exceptional surface finishes, crucial for medical applications.

Electronics: Precision is essential in the electronics industry, where delicate components require fine grinding and cutting. Diamond plated tools play a pivotal role in shaping semiconductors, ceramic substrates, and other electronic components with microscopic precision.

Tool and Die Making: Tool and die manufacturers use diamond plated tools to create molds, dies, and precision cutting tools. These tools provide the accuracy needed to produce intricate and high-quality components.

Stone and Glass Processing: In the construction and architectural industries, diamond plated tools are used for cutting and shaping stone, glass, and composite materials. They offer the precision and control necessary for creating custom designs and finishes.

Fiberglass and Composites: Electroplated grinding tools are indispensable for shaping and refining composite materials used in many applications. From boat hulls to automotive body parts to architectural panels, their ability to provide precise shaping and surface finishing ensures the structural integrity and aesthetics of fiberglass and composite products.

The Competitive Edge of Electroplated Grinding Technology

In conclusion, electroplated grinding wheels offer an impressive array of advantages, including consistent distribution of abrasive particles, a robust bond between abrasive and substrate, fast and free cutting action, and an innovative reconditioning option with Strip and Replate. These benefits combine to deliver long-term cost savings, which establish electroplated grinding wheels as the preferred choice for precision machining across a diverse array of industries.

To harness the advantages of electroplated diamond and cbn grinding wheels for your specific machining needs and see the cost savings, consider partnering with trusted grinding wheel manufacturers like CDT, dedicated to delivering exceptional quality and performance.

High Flying Engineering Firm Says Fond Farewell to Founder Steve

(From left to right) Justin Hughes, David Morris, Peter Hughes, Stephen Noakes, and Michaela Lawton with Stephen’s inscribed nickel-plated mould, which was presented to him as a retirement gift at the celebration in December of 2023.

A specialist engineering company that keeps the world’s airlines flying will reach new heights thanks to investment from its new American owners, according to one of the firm’s founders. 

Former production director Steve Noakes, 67, from Trefriw, in the Conwy Valley, was speaking at a presentation ceremony to mark his retirement from Continental Diamond Tool in Kinmel Bay which is celebrating its 40th anniversary this year.

Among his leaving gifts was a nickel plated version of the graphite mould for a diamond rotary dresser of the type used to grind the turbine blades of Rolls Royce aero engines, with the signatures of each of his 40 colleagues engraved onto it. 

Steve was one of the eight people who established the niche company as Consort Precision Diamond in 1984, specialising in the manufacture of diamond-encrusted rotary dressers and grinders.

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

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

The company was acquired and rebranded in 2018 by American outfit Continental Diamond Tool which has its headquarters in New Haven, Indiana.

Father-of-two Steve was the last man standing because all the other members of the original team had already retired.

He left “safe in the knowledge” that the company was in good hands. having seen the new management team investing £1.6 million to launch a second production line to make electro-plated grinding wheels, with record profits and sales soaring by 70 per cent.

Steve said: “I am extremely proud of what we have achieved, employing people for 40 years in skilled, well paid jobs.

“I’m also very proud that we’re now part of Continental Diamond Tool. Acquisitions can be messy affairs but this was actually a really happy process.

“They have the same mindset as a family-oriented company, looking after their employees and building a successful business with a very good future. The fit is excellent because they can invest more than we were able to as an independent company.”

He was delighted by the “perfect” gift of the inscribed nickel-plated mould which was presented by his old boss, the original managing director, Dave Morris, who came back for the emotional occasion.

He said: “Steve made a huge contribution – he’s a real diamond. In one sense this is a sad day but it’s also a good one for him because we know our legacy is safe. They’re a good bunch of people.”

There were also good wishes from CDT president, Nick Viggiano, who said: “We will always be indebted to Steve and his fellow founders for their grace, helpfulness and goodwill in managing the transition to the new ownership.

“Steve played an integral role in building a very successful company with a global reputation for excellence in a very competitive niche market. He should be incredibly proud of what he achieved.”

The current managing director, Jeff Wirth, adds, “We are determined to build on those firm foundations and continue to grow and prosper as we look forward to the next 40 years of success.” 

The baton has also been passed to current production manager Justin Hughes, son of the firm’s original technical director, Peter Hughes.

He said: “We now have backing behind us which enables us to push forward and aim at new markets because we have a big safety net behind us.  It gives us reassurance.

“I spoke to our new managing director, Jeff Wirth, who was incredibly complimentary about the existing workforce and said how brilliant it was and the high level of skill and work ethic here.”

It was a sentiment echoed by finance manager Michaela Lawton who said: “We have a lovely team here and everyone’s really very excited about the future.

“We’ve had an investment of £1.6 million and the company’s been on an upward trajectory in terms of growth, turnover and profit and being able to diversify our product range is the next step forward.

“It’s great for Steve, who’s been with the company from the very beginning, to see that that the company is going to continue to grow and expand into new markets.

“Every business goes through a life cycle and the acquisition happened at a perfect time with the original founders reaching retirement age. It was a marriage made in business heaven and the sky’s the limit.”

Related Links:

https://www.insidermedia.com/news/wales/engineering-firm-set-to-reach-new-heights

https://www.herald.wales/north-wales/high-flying-engineering-firm-says-fond-farewell-to-founder-steve/

https://www.northwalespioneer.co.uk/news/24049229.kinmel-bay-engineering-firm-says-fond-farewell-conwy-valley-founder/

https://www.wales247.co.uk/high-flying-engineering-firm-says-fond-farewell-to-founder-steve

https://www.rhyljournal.co.uk/news/24049229.kinmel-bay-engineering-firm-says-fond-farewell-conwy-valley-founder/

Releasing "The Grinding Chronicles" Your Gateway to Optimized Grinding Processes

Exciting news for those involved in precision grinding! This month, Continental Diamond Tool (CDT) proudly unveiled "The Grinding Chronicles," a video series aimed at unraveling the complexities of grinding techniques. Led by our team of expert product and application engineers, this series aims to empower and educate individuals seeking to enhance efficiency and reduce costs in their grinding operations.

Watch Episode 1: Introduction to The Grinding Chronicles with Nick Viggiano

Episode 1

Introduction to The Grinding Chronicles

The series kicks off with Nick Viggiano, President of CDT, extending a warm welcome to viewers. He introduces the team and outlines the series' core mission: addressing common grinding queries and tackling significant challenges encountered during the grinding process. With decades of expertise in crafting precision grinding products and innovative solutions, CDT promises to share valuable insights throughout this series.

Watch Episode 2: Benefits of Using a Grinding Lab with Harrison Sheldon

Episode 2

Harnessing the Power of a Grinding Lab

In episode two, CDT Application Engineer Harrison Sheldon explores the benefits of using a grinding lab to improve grinding processes. Relying solely on personal judgments during grinding can lead to mistakes. Sheldon shows how sensors gather objective data, providing more accurate measurements. Discover how CDT's lab collects and analyzes data in four critical areas: Cut, Wear, Quality, and Cost.

Engage with The Grinding Chronicles

"The Grinding Chronicles" isn't just a viewing experience; it's a platform tailored to your needs. CDT invites active participation, encouraging viewers to submit their questions, challenges, and episode ideas. This series aims to address specific concerns of industry professionals who use our products.

Email us at TheGrindingChronicles@cdtusa.net with your questions, and we will do our best to answer them.

Explore Further with CDT's Grinding Lab

CDT's grinding lab has been a game-changer for those who have used it, enhancing operations through data-driven decision-making rather than relying on instinct. It can simulate various grinding environments and offers on-site analysis, ensuring minimal downtime for CDT customers. Plus, it’s complimentary for our customers to use.

In episode 2, you can witness how lab-generated data optimizes real-world grinding processes. Sheldon demonstrates how manipulating and measuring variables, like wheel speed, can help make smarter choices, yielding better results and cost savings.

If you're interested in leveraging a data-centric approach for process development or optimization, reach out to us at TheGrindingChronicles@cdtusa.net. Improving efficiency and precision is what we do.

Subscribe and Stay Tuned

Subscribe to CDT's YouTube channel to catch new episodes of "The Grinding Chronicles." Here are some upcoming topics you won’t want to miss: 

• Coolant and Its Effect on Grinding Performance

• Conventional Abrasives vs. Superabrasives

• Q-Prime, G-Ratio, Speeds & Feeds

Year-End Update from Continental Diamond Tool President Nick Viggiano

In this video update, Continental Diamond Tool's President, Nick Viggiano, offers a candid overview of the company’s progress in 2023 and its plans for 2024. Viggiano's report centers on CDT's commitment to meeting customer needs and improving the partnership experience.

Viggiano highlights three core customer priorities: Quality, Delivery, and Price. First, he discusses CDT's efforts to bolster quality by investing in new measuring equipment, tightening tolerances, and expanding CDT’s engineering team to refine customers' processes and minimize waste.

In his message, Viggiano acknowledges delivery issues in the past year that were exacerbated by global supply disruptions, growing pains, and staffing shortages. He assures viewers of proactive measures for 2024. CDT has made significant investments in equipment and recently initiated an expansion project to enhance production capacity and mitigate delays.

Regarding the company’s approach to pricing, Viggiano emphasizes CDT's success in negotiating favorable prices with vendors due to its growth in the industry. “We’ve been able to flex our muscles and buy larger volumes of material to achieve better pricing, “says Viggiano. “This has been very evident over the last handful of years when our major competitors imposed multiple price increases per year or double digit increases annually. At CDT, we’ve been adamant about keeping increases to an absolute minimum.”

In addition, Viggiano highlights this year’s release of CDT's Evo Hybrid Bond wheels, designed to optimize operations for manufacturers of round tools and inserts. Customers are encouraged to reach out to CDT’s sales team to explore these new wheels for potential benefits.

Evo’s advancement in hybrid bond technology is the latest innovation to come from CDT’s expert engineering team and state-of-the-art grinding lab. In the video, Viggiano extends an invitation to customers to utilize CDT's grinding lab at no cost, emphasizing the company's commitment to supporting customers to achieve much better cycle times and reduce waste.

Finally, Viggiano announces an upcoming video series, "The Grinding Chronicles," to be released on CDT’s YouTube channel on January 4th. The series is set in CDT’s grinding lab where engineers will use the testing center to address grinding challenges and showcase its capabilities.

CDT's unwavering focus on continuous improvement, evident through process enhancements, equipment upgrades, and team empowerment, underscores the company's commitment to assisting customers in staying competitive. As Viggiano concludes, “We’re committed to helping you gain the edge you need to secure new business.”

Watch this video of Nick Viggiano's President's Report for a comprehensive look at Continental Diamond Tool’s customer-focused approach and plans for the future.

Join Nick Viggiano, President of Continental Diamond Tool, as he shares a candid overview of our progress in 2023 and plans for 2024. Learn how CDT's efforts to enhance quality, delivery, and fair pricing benefit our valued customers.

Understanding Precision Polishing Film and Its Role in Precision Manufacturing

In precision manufacturing, achieving a flawless surface finish is fundamental for product functionality and aesthetics. Precision polishing film, a specialized material used in the final polishing stages, stands as an important tool in refining and perfecting surface quality to meet rigorous industry standards.

What is a Precision Polishing Film?

At its core, precision polishing film is crafted by coating an abrasive material onto a flexible polyester substrate. This film refines surfaces and ensures precision across a variety of materials including metals, ceramics, optics, and semiconductor wafers.

3 Types of Precision Polishing Film

There exists several varieties of precision polishing film, each tailored to specific surface refinement requirements:

• Mirror Film: Noted for its fine-graded abrasive grains uniformly coating the polyester film, mirror film offers superior sanding capability and durability.

• Lapping Film: With micron-graded abrasive grains uniformly distributed in resin adhesive, lapping film consistently delivers accurate and high-quality finishes.

• Diamond Lapping Film: The diamond abrasive in this lapping film makes it particularly suitable for precision finishing of extremely hard substances or challenging materials such as ceramic and ferrite compounds. 

Broad Industry Applications 

Precision polishing films are useful for many applications across diverse industries. They play an essential role in enhancing the surface of roll and shaft materials, flat displays, commutator shafts of micro motors, and magnetic heads and disks. These films are equally prevalent in the manufacture of many disc applications such as plastic lenses, optical devices, fibers, and painted surfaces. Additionally, sheet applications like print circuit boards and optical devices incorporate precision polishing film in their manufacturing processes.

Extending Beyond Our Core Specialties

While Continental Diamond Tool (CDT) is known for its high-quality, custom diamond and CBN grinding products, alongside precision diamond dressing tools, our commitment to excellence encompasses more than our specialized niche. Our expertise extends to supplying other essential grinding and polishing solutions, including precision polishing film, to address the evolving needs of our customers. This highlights our dedication to addressing a wide array of precision manufacturing requirements.

The CDT Advantage:

• A Legacy of Quality: We ensure consistent, superior-grade products that adhere to stringent industry standards.

• Customized Solutions: Our skilled technicians offer customized solutions, ensuring optimal performance for unique customer requirements.

• Comprehensive Support: From concept to implementation, our expert team provides guidance to maximize productivity and achieve the best possible outcomes.

• Expanded Offerings: Alongside our core expertise, we equip customers with grinding and polishing essentials, including precision polishing film, ensuring a comprehensive suite of tools for optimal surface refinement.

Backed by Uncompromising Quality

Our precision polishing films, like all products supplied by CDT, are made of the highest quality materials with various thicknesses available, starting at a minimum of 25 microns. The polyester film’s uniform thickness, smooth surface, and strength provides strong resistance to pulling and tearing forces, with less elasticity. 

This table outlines the extensive variety of options available:

For detailed information on our precision manufacturing grinding and finishing products and their benefits to your operations, contact us today.

Continental Diamond Tool Limited Soars with Record Sales Driven by £1.6 Million Investment

(From left to right) Michaela Lawton, Jeff Wirth, Troy Giacherio, and Justin Hughes in Continental Diamond Tool Limited’s new plating lab.

Continental Diamond Tool Limited — CDT’s subsidiary stationed in Kinmel Bay, Conwy, in North Wales— is experiencing an era of remarkable growth thanks to a substantial £1.6 million investment initiative. According to Jeff Wirth, the Managing Director, this rapid expansion is a result of a perfect blend of Welsh dedication and backing from its American stakeholders.

"As part of our expansion strategy, we opened a second production unit, which has facilitated the establishment of a new electro-plating operation. With support from the Welsh Government, this move marks a significant leap for us," said Wirth.

Continental Diamond Tool Limited is a niche outfit, one of merely two similar enterprises in the UK that specializes in crafting diamond-encrusted rotary dressers and grinders. The team designs their custom products for diverse manufacturing sectors like aerospace, automotive, medical, and semiconductor industries.

"In aerospace, our rotary diamond dressers play a pivotal role in crafting engine parts for prominent aircraft like the Boeing 777 and 787 Dreamliner, as well as the Airbus A330-A380 series," commented Wirth. These aircraft parts are notably crafted at the Airbus facility in Broughton.

"Over 60% of our products find their way to 30 countries globally, experiencing substantial growth across Europe, Asia, and North America," added Wirth.

Originally founded as Consort Precision Diamond, the company will be celebrating its 40th anniversary in April of next year (2024). In 2018, it underwent a timely transition when Continental Diamond Tool Corporation acquired it. During the COVID-19 pandemic, the company showed resilience amid adversity as it pivoted its product range to mitigate a significant loss of orders in one of its largest sectors due to grounded passenger planes.

"It would have sunk most companies, but we had already started our diversification and a pretty significant culture change here," remarked Wirth during a visit from the States. "Sales are now at a record high. Over the last five years, our Rotary Diamond Dresser product line in Kinmel Bay has seen remarkable growth of over 70%, despite the negative effects of COVID," he continued.

CEO Nick Viggiano noted, "We believe in the workforce here, we believe in the people, their work ethic, their can do spirit, and the pride they take in their work. At CDT headquarters in New Haven, Indiana, the culture is the same. When you take modern technologies and join it with that culture, it’s a recipe for success.”

"The new energy and substantial investment brought by the new owners has been a game-changer," echoed Michaela Lawton, the finance manager. "We've also had a good relationship with the Welsh Government for some time. The latest support with the £90,000 we received from the Smart Cymru fund helped fast-track the new technology that we introduced through the electro-plated product."

The project has been a source of great pride to production manager Justin Hughes who’s been working at the Kinmel Bay site for the past 17 years.

He said:  “We’ve got the backing of the American parent company behind us which enables us to push forward with investment in machinery and people to aim at new markets. It gives us reassurance and confidence as we continue to grow and develop.”  

"The company is on an upward trajectory in terms of growth, turnover, profit, and being able to further diversify our product range is the next step forward,” adds Lawton. “It's a very exciting place to work, and the sky really is the limit.” 

Related News Links:

https://www.rhyljournal.co.uk/news/23936389.kinmel-bay-engineering-firms-sales-jet-propelled-1-6m-investment/

https://www.business-live.co.uk/manufacturing/global-engineering-firm-north-wales-28144996

https://www.herald.wales/north-wales/global-engineering-firms-record-sales-are-jet-propelled-by-1-6m-investment/

http://www.baysideradio.co.uk/news/kimmel-bay-global-engineering-firm-propelled-by-1-6m-boost-8260

Continental Diamond Tool Corporation Breaks Ground on Major Expansion Project, Creating Job Opportunities

Continental Diamond Tool Corporation (CDT), manufacturer of diamond and cBN grinding products, marked a significant milestone as it officially broke ground on an ambitious expansion project at its headquarters in New Haven, Indiana. This development was announced by Shane Vardaman, President of Sales at CDT, in a video statement, which highlighted the company's dedication to growth, customer service, and innovation.

The $6 million expansion, which will add 70,000 square feet to the existing facility, will bring CDT's headquarters to an impressive total of 200,000 square feet. This expansion not only extends CDT’s capacity for delivering technologically advanced solutions to its customers but also brings job opportunities for the local community. The additional space will facilitate the company's plans to broaden its product offerings and enhance its customer service capabilities. It is anticipated that approximately 60 jobs in manufacturing, engineering, and sales will be added over the next 18 months.

In his video statement, Shane Vardaman expressed gratitude for the support received from CDT's loyal customers throughout the company's 50-year journey. 

"2023 marks 50 years of excellence in superabrasives … and it's also been a year of incredible growth. I want to personally thank all of our customers for your unwavering support," Vardaman said. "Whether you're new to the CDT family, or you've been with us for decades — thank you for your trust and commitment. We look forward to a future of continued growth, dedication, and innovation."

The expansion project demonstrates CDT's commitment to advancing grinding technology and its mission to deliver top-quality products like grinding tools and services to customers. The additional space will enable CDT to enhance its offerings and meet the changing requirements of various industries.

In this video of the groundbreaking on the company’s YouTube channel, the public can witness this important milestone in the company's history:

News of CDT’s expansion was also featured in this article in The Journal Gazette of Fort Wayne, Indiana.

Mastering Precision Grinding with Diamond Rotary Dressers for Plunge Dressing

When it comes to precision grinding, achieving exceptional accuracy and control is paramount. One of the key techniques that enable this level of control is Plunge Dressing through the use of a precision diamond rotary dresser. In this blog, we will explore Plunge Dressing and the crucial role it plays in the high tech manufacturing industry. We will also take a step back in time to uncover the history of this essential tool.

Understanding Plunge Dressing

Plunge Dressing is a specialized method used in precision grinding requiring the tightest tolerance controls. The process involves “plunging” a precision rotary diamond dresser with the form of the finish part vertically into the grinding wheel. This approach allows for a mirror image of the part to be put into the grinding wheel which is then used to grind the finished parts to the highest levels of accuracy achievable.

The History of Plunge Dressing

Plunge Dressing, in its essence, is as old as precision grinding itself. It evolved alongside the broader history of abrasive tools and precision engineering, with the diamond rotary dresser as a key component.

The roots of Plunge Dressing can be traced back to the early days of industrialization when grinding processes were becoming essential for the production of precision components. As the manufacturing industry advanced, the need for higher precision, tight tolerances, and complex profile (geometry) control became apparent. This led to the development and refinement of techniques, including the use of the precision diamond rotary dresser or diamond dressing wheel, to enhance the grinding process.

Since 1984, Continental Diamond Tool Limited, then called Consort Precision Diamond Company, has been making precision Hand-Set “Sintered” Rotary Diamond dressers. In 1995, CDT LTD made waves with its development of an electroforming process that greatly reduced the process time for Reverse Plated Diamond Rotary Dressers. With these advances and revolutionary technology in both Sintered and Reverse Plated manufacturing methods, precision Rotary Dressers are now more affordable and accessible to a greater number of industries.

The Benefits of Plunge Dressing with a Diamond Rotary Dresser

Plunge Dressing with diamond rotary dresser, offers a range of benefits that make it a preferred choice in precision grinding:

1. Precise Profile Control: Plunge Dressing with a diamond rotary dresser enables the precise shaping of intricate profiles on workpieces. This level of control is invaluable in applications where tight tolerances and intricate shapes are required with tolerances of 1um or better.

2. Reduced Heat Buildup: The controlled plunge of the diamond rotary dresser results in precise truing and conditioning of the grinding wheel.  This is especially important for materials that are sensitive to heat, helping to prevent thermal damage and maintain workpiece integrity.

4. Consistency and Quality: Plunge Dressing with a diamond rotary dresser ensures consistency in material removal, resulting in a high-quality surface finish on workpieces. This consistency is crucial for producing precise components with minimal variation.

The Mechanics of Plunge Roll Dressing

Plunge roll dressing involves a specific mechanical process. Here's a glimpse of how it works:

1. Preparation: To start, the diamond rotary dresser is set up and aligned with the grinding wheel.

2. Vertical Movement: Then the dresser is moved vertically into the spinning grinding wheel. The depth of penetration is precisely controlled to ensure the desired material removal.

3. Material Removal: As the diamond rotary dresser engages with the grinding wheel, it removes material from the wheel's surface. This process allows for the desired profile or shape to be formed on the wheel.

4. Controlled Withdrawal: After the material removal process is complete, the diamond rotary dresser is withdrawn from the grinding wheel. This is done with the same level of precision and control to maintain the desired profile.

APPLICATIONS for Plunge Dressing with a Diamond Rotary Dresser

Plunge-style diamond rotary dressers find applications in many industries, such as:

Aerospace: In the aerospace industry, where precision and tight tolerances are paramount, plunge dressing with a diamond rotary dresser is used to shape critical components for aircraft and spacecraft.

Medical Devices: Plunge-style diamond rotary dressers are essential for creating intricate and precise components in medical devices to ensure their safety and effectiveness.

Automotive: This type of diamond rotary dresser is regularly employed to craft precision parts for the automotive industry, contributing to the performance and longevity of vehicles.

IN SUMMARY

In the world of precision grinding, plunge dressing with a diamond rotary dresser stands out as a technique that empowers manufacturers to achieve the highest levels of precision and quality. Its control and consistency make it an invaluable tool for industries where tight tolerances and intricate profiles are the order of the day.

Our Consort Precision™ line of Diamond Rotary Dressers offers versatility in design, with custom plunge form dressers available in sintered or reverse plated variants. The plated plunge form rotary dressers have the extra benefit of being able to hold tighter tolerances, where as Sintered Rotary Dressers can have shorter lead times and hold up better in rough environments. Both Sintered and Reverse Plated Rotary Dressers can be manufactured and shipped from our manufacturing facilities in either North America or Europe.

Celebrating 50 Years of Excellence: Continental Diamond Tool Corporation's Remarkable Journey

This October marks a truly momentous milestone in our journey - the celebration of Continental Diamond Tool Corporation's 50th anniversary. For half a century, we've been dedicated to pioneering excellence in superabrasive tool manufacturing, and this journey of growth and innovation has been nothing short of extraordinary.

1973: The Humble Beginnings

Our founder, Ray Viggiano, took the first monumental step in the fall of 1973 when he opened the doors of our first 4,500 sq. ft. building on Hartzell Street in New Haven, Indiana. Little did we know that this was the inception of a legacy that would span decades.

A Half Century of Innovation and Expansion

Over the years, we have accomplished countless milestones:

• 1973 Continental Diamond Tool Corporation is established.

• By 1974, production of Metal Bond Diamond and CBN products and Diamond Stationary Dressers ramps up, setting the foundation of our expertise in superabrasives.

• 1978 saw the launch of our Resin Bond product line, expanding our product range and capabilities.

• Fast forward to 1984-1985, we ventured into the Plated product line, diversifying our offerings to meet evolving industry needs.

• In 1988, we attended our first trade show, marking the beginning of our active presence in industry events and networking opportunities.

• During the 1990s, we experienced steady growth, fueled by a dedicated team of loyal employees. Many of them have been working at CDT for decades, contributing their expertise and commitment to quality and customer service.

• 1997 marked a significant expansion with the doubling of our Hartzell Street building's size to 20,000 sq. feet.

• In 2012, we underwent our third expansion, doubling the Hartzell Street building again to 40,000 square feet.

• 2014 was the year we proudly launched our Vitrified product line.

• 2015 brought another expansion, increasing our Hartzell Street building's size to an impressive 55,000 sq. feet.

• In 2016, we acquired Sierra Diamond, a manufacturer of Metal Bond tools in Auburn, California, expanding our reach and welcoming West Coast customers to the CDT family.

• The year 2017 was marked by the launch of our Resin Hybrid Bond products after months of dedicated research and development.

• In 2018, we solidified our global presence with the acquisition of Consort Precision Diamond Company Ltd., a leading manufacturer of Diamond Rotary Dressers in the United Kingdom. Additionally, we completed construction and moved into our brand-new 130,000 sq. foot manufacturing and office facility on Rose Avenue in New Haven, Indiana, setting the stage for our future.

• Another acquisition of diamond grinding products distributor Access Diamond in California in 2019 further increased CDT’s market share.

• 2019 also brought the first expansion of our Rose Avenue location, adding 15,000 sq. ft. to make room for our state-of-the-art Grinding Lab for research and development that opened in 2020. This space allows us to enhance product performance and spur innovation for customers in specific industry applications.

• Also in 2020, we acquired Jalsons International, a manufacturer, and supplier of Diamond Stationary Dressers, further expanding our capabilities and welcoming more customers into our extended family.

• The year 2021 witnessed our investment in robotic automation and the addition of a third shift at our primary manufacturing facility in New Haven, Indiana, to meet increasing customer demand.

• In 2022, we proudly launched the next generation of Hybrid Bond Technology with the specialized EVO line of custom grinding products for the Cutting Tool industry.

• 2023 has been a year of remarkable growth as we acquired Alpex Wheel Company in New Jersey, expanding our customer base on the East Coast. In line with this, Consort Precision Diamond changed its name to Continental Diamond Tool Limited, marking its growth as the European subsidiary of Continental Diamond Tool Corporation. We also began production of Diamond Rotary Dressers at the Rose Avenue location.

FROM PAST TO FUTURE

This year, 2023, is indeed a special one as we celebrate half a century of dedication, innovation, and excellence in superabrasive tool manufacturing. We're immensely grateful for the unwavering support of our employees, customers, and partners who have been integral to our journey.

As we commemorate this significant milestone, we reaffirm our commitment to pushing the boundaries of what's possible in superabrasive tools. Here's to the next 50 years of excellence and innovation! Thank you for being a part of our incredible journey.

The Science Behind Resin Bond Grinding Wheels: How They Work and Where They Excel

In the world of machining and precision grinding, engineers and manufacturers are constantly seeking ways to enhance efficiency and finish parts to increasingly tighter tolerances. A key player in this arena is the Resin Bond superabrasive grinding wheel. This remarkable technology has revolutionized the way hard materials are shaped and finished. In this article, we will look at the science behind Resin Bond grinding wheels, understanding how they work and why they excel in various applications.

Understanding the Basics

Before we dive into the intricacies of Resin Bond grinding wheels, it is essential to understand the core fundamentals that govern their operation.

1. Resin Bond: Resin is a polymeric (plastic) material that can be formed under specific conditions. At Continental Diamond Tool, our Resin Bond products are created using phenolic and polyimide resins, which are combined with conventional abrasives, superabrasives, and metal powders to form specific grinding structures. The thermosetting resins are the bonding agent that hold the abrasive materials (typically Diamond or CBN) in place. Once blended together, wheel compositions are “hot pressed” to specific sizes & shapes in special molds, and the resins are cured.  After hot pressing to near-net shape, they are machined to final dimensions and tolerances for customer use. Resin Bonds are highly regarded for their ability to provide a firm mechanical grip on abrasive particles, ensuring stability during the grinding process. It is this bonding, combined with flexibility of grinding structures, that allow for the customization required for efficient grinding of a variety of materials and applications.

2. Abrasive Material: Abrasive materials are used in grinding, cutting, and shaping processes to remove material from workpieces. They differ in terms of hardness, durability, and efficiency. Superabrasive materials are a special class of abrasive known for exceptionally high hardness, wear resistance, and cutting efficiency. The two superabrasive materials we use at Continental Diamond Tool are Diamond and Cubic Boron Nitride (CBN). Diamonds are ideal for grinding and cutting extremely hard materials like ceramics, glass, and precious stones, while CBN is used for grinding ferrous materials like steel and hardened alloys. When superabrasives are embedded in a resin matrix, it creates an incredibly effective cutting and grinding tool when compared with conventional abrasives like Aluminum Oxide and Silicon Carbide grinding wheels.

3. Wheel Structure: The arrangement of abrasive material and fillers within the resin matrix forms the wheel's abrasive surface. These abrasives can be designed in various shapes and concentrations, depending on the intended application. Variables like abrasive grain type, size, shape, concentration, bond type, porosity, wheel grade, and design are carefully engineered to determine the wheel's performance characteristics: its cutting ability, surface finish quality, heat dissipation, suitability for specific grinding applications, and more.

How It Works

Resin Bond superabrasive wheels are employed in a wide range of applications, from grinding high hardness materials to sharpening other Diamond or CBN cutting tools. For optimal efficiency, Resin Bond grinding wheels perform best with applications that are well-suited to the way these wheels interact with the workpiece.

1. Cutting Action: When a Resin Bond wheel is brought into contact with a workpiece, the Diamond or CBN abrasives on the wheel's surface come into play. Superabrasives are exceptionally hard, making them capable of cutting through even the toughest materials.

2. Heat Generation: As the wheel cuts through the workpiece, friction generates heat. Both Diamond and CBN are excellent thermal conductors, but Resin Bonds do not inherently conduct heat well. As a plastic, Resin Bond deteriorates at pretty low temperatures compared with other bonds. Its wheel performance is best when coolants and compositions are tailored for “dry grinding” applications. In applications where heat dissipation is a priority, Resin Bond formulations can be manipulated by adding conductive metals such as copper or aluminum to remove heat more efficiently.

3. Wear and Tear: Grinding forces erode equipment over time. Unlike traditional abrasive wheels that wear down quickly and require frequent dressing to stay effective, Resin Bond superabrasive wheels can be formulated to be self-dressing. As the abrasive diamonds wear, new grains are exposed, maintaining a consistent cutting edge throughout the wheel's life.

4. Edge Stability: Edge stability refers to a tool’s ability to maintain the sharpness and integrity of its cutting edge over time. The combination of the high hardness superabrasive with the strong mechanical bond of the resin binder provides excellent edge stability and sharpness, which makes for more efficient grinding. Good edge retention increases productivity and reduces cycle times through less frequent tool changes and consistent cutting performance. 

5. Performance: Precision tolerances and highly controlled surface finishes are where Resin Bond Diamond and CBN wheels really shine. Their remarkable capabilities in these areas are especially crucial in industries like optics, where the tiniest imperfection can lead to significant quality issues.

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The Master of Surface Finish

Here are the top 8 reasons why the unique characteristics of Resin Bond make it favored across industry applications that require fine surface finishes:

1. Uniform Abrasive Distribution: Resin Bond wheels are manufactured using a carefully controlled process that results in a uniform distribution of abrasive particles throughout the wheel. This uniformity ensures that the wheel removes material evenly across the workpiece, preventing irregularities in the surface finish.

2. Self-Dressing Properties: The self-dressing action of Resin Bond grinding wheels helps maintain a consistent cutting edge, which is essential for achieving a smooth surface finish.

3. Cooler Grinding: Diamond and CBN are already excellent conductors of heat, and resin bonds can be formulated with conductive metals to further aid in heat removal. This improved heat dissipation lessens the likelihood of thermal damage, such as metallurgical changes and micro-cracking, which negatively impact surface quality.

4. Flexibility and Conformability: Compared to Vitrified and Metal Bonds, Resin Bonds are relatively soft and flexible, which is advantageous for contour grinding and achieving intricate shapes. This flexibility allows the wheel to conform to the workpiece's surface, ensuring the consistent contact needed for a smoother finish.

5. Controlled Grit Size and Concentration: Resin Bond wheels can be precisely engineered with specific grit sizes and concentrations of abrasive particles to optimize for surface finish requirements. Finer grit sizes and lower concentrations typically produce finer surface finishes, such as those required by polishing applications.

6. Reduced Wheel Wear: As mentioned earlier, Resin Bonds wheels tend to maintain their shape and cutting efficiency over a longer period than conventional grinding wheels. This lower wear rate contributes to a consistent surface finish.

7. Minimized Wheel Loading: Resin Bond wheels are less prone to loading, which occurs when swarf or material being ground adheres to the wheel's surface. Loading can negatively impact the surface finish, but Resin Bond wheels tend to resist this issue, helping to maintain consistent performance.

8. Wide Range of Abrasive Options: Resin Bond wheels are compatible with a wide range of abrasive materials, including Diamond and CBN. By tailoring the abrasive to the specific material being ground, it further enhances fine grinding efficiency.

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Areas Where Resin Bond Excels

Resin Bond superabrasive wheels are among the most popular and widely used bond types for a number of other compelling reasons.

1. Versatility: These wheels can be tailored to suit a wide variety of applications, making them indispensable in industries as diverse as automotive, aerospace, medical,and electronics manufacturing.

2. Precision: The accuracy and precision achieved with Resin Bond superabrasive wheels are unparalleled. They produce intricate shapes and finishes with exceptional consistency.

3. Longevity: Thanks to self-dressing properties, Resin Bond superabrasive wheels have a longer operational life compared to conventional abrasive wheels.

4. Reduced Waste: The minimal wear on these wheels results in less material waste, making them an eco-friendly choice for many industries.

5. Reduced Downtime: Less frequent wheel changes and dressing requirements mean reduced downtime and increased productivity for manufacturing operations. Additionally, these tools dress easily for added convenience. 

6. Cost-Efficiency: Despite an initial higher cost compared to conventional counterparts, the longevity and efficiency of a Diamond or CBN Resin Bond tool often result in cost savings over time. 

7. Hybrid Variants: Hybrid bonds combine characteristics of different bond types. This is especially common with Resin Bond wheels. For example, a hybrid wheel might have a blend of resin and metal bonds to balance precision with heat dissipation.

The Bottom Line

Resin Bond grinding wheels are a testament to advanced materials science and engineering precision. Their ability to cut, grind, and shape materials with unparalleled accuracy and efficiency has made them indispensable in numerous industries, especially in high-precision production grinding applications of hard materials.

These versatile grinding wheels are employed in tasks ranging from centerless and cylindrical grinding to surface and creep feed grinding. They cater to materials as challenging as tungsten carbide, ceramics, and stainless steel, where precision and surface finish are paramount. Resin Bond wheels also excel in cutoff, roll grinding, tool and cutter, saw and knife sharpening, PCD grinding, and surgical tool blade sharpening applications, showcasing their adaptability across the spectrum of manufacturing and fabrication needs. Whether it's the intricate precision required for surgical tools or the robust grinding demands of hardened steel, resin bond grinding wheels are trusted companions for achieving exceptional results.

As technology continues to advance with hybrid bond types, it is likely that Resin Bond superabrasive wheels will play an even more significant role in the quest for perfection in machining and precision grinding. Their adaptability, accuracy, and longevity make them a driving force behind innovation in manufacturing processes and a cost-efficient grinding solution for many industries around the world.

The Story Behind Our Precision Grinding Solutions at Continental Diamond Tool Ltd.

At Continental Diamond Tool Limited, our 40 years of success has been built by delivering the finest custom Diamond Rotary Dressers available in the market. Also called Diamond Rolls, these tools are used extensively in a growing number of grinding operations to primarily facilitate the transfer of highly accurate repeated configurations onto components. What makes a Consort Precision Diamond Rotary Dresser stand out can be summarized in four key aspects: technology, expertise, process, and quality or product excellence. As we have expanded into other product lines, we bring that same commitment to every precision grinding product we produce.

Cutting Edge Technology

In a plunge-style dresser the Rotary Diamond Dresser is mounted onto a spindle of a drive unit which in turn is mounted onto a slideway arrangement that allows the formed periphery of the dresser to infeed into a grinding wheel, thereby transferring the desired shape into it. The form, or configuration, can then be 'ground' on to the component. Plunge dressers are especially accurate for precision grinding as there is no lost form or geometry due to machine movements. Plus, the dressers can be held to submicron levels of accuracy.

Traverse dressing is a grinding wheel dressing technique where the diamond rotary dresser traverses across the surface of the grinding wheel to create a specific profile or shape. Traverse Disc Dressers allow you the flexibility to make profile changes or dress in completely new profiles with the same tool, reducing down time for wheel change overs or roll changes.

INDUSTRY EXPERTISE

Such Industries as the Automotive and Aerospace as well land based Turbine Engine production units employ large quantities of Rotary Diamond Dressers. Typically, within the Aero manufacturing industry, such components as Turbine Blades and Nozzle Guide Vanes as well as Flap Actuating Shafts require their intricate features to be ground with grinding wheels that have been formed with Rotary Diamond Dressers. As can be seen reference is made on our following pages to the many applications within the automotive industry.

CDT Ltd. can offer expertise in the selection of the most appropriate type of Rotary Diamond Dresser by reference to the configuration required and to the grinding machine on which it is to be used. Basically, three processes are employed. Handset Sintered, Random Set Sintered and Reverse Plated. Within each of those categories, selection of diamond type and their placement into the periphery of the Rotary Dresser, plays a major part in determining its operational life and performance. Even before its establishment in 1984, the company’s principals and a large proportion of its employees had many previous years experience in the manufacture of Rotary Diamond Dressers. Bringing with them unique knowledge of the industry, CDT Ltd. — then Consort Precision Diamond — quickly established itself with this one product into the global market of prime and subcontract component manufacturers, earning the respect of competitors and customers alike.

AWARD-WINNING PROCESSES

In respect to the Reverse Plating technique, at Continental Diamond Tool Limited we are particularly proud of the fact that we have been awarded the accolade of winning the BOOST award in the U.K. in 1995 for the design and development of a high speed plating process which dramatically reduced previous lengthy plating times. This achievement gave us a competitive edge against alternative suppliers and satisfied the reduced lead times that customers continue to demand. In the same period, we gained the S.M.A.R.T 1995 award for the development of the electroforming process as an acknowledgement of the reduction in the process time employed in the manufacture of Reverse Plated Rotary Diamond Dressers. CDT Ltd. proudly holds the ISO 9001:2015 Registration Certificate for its Quality Management Systems.

A FOCUS ON PRODUCT EXCELLENCE

The Consort Precision name has become synonymous for outstanding quality and performance in Diamond Rotary Dressers. Since 1984, we have been perfecting the design, development, manufacture, install and maintenance of this advanced dressing technology. This long history with a singular focus has given us the unique ability to provide our customers with the best solution technology can offer. We have the engineering, design, manufacturing and staff resources to supply the highest quality Diamond Rotary Dressers available on the market. Our specialized experience ensures each product we supply is the optimum choice for each individual customer, however demanding and complex the configuration. If an application calls for traverse- or plunge-style rotary dressing, Consort Precision™ Diamond Rotary Dressers are the best tool for the job.

With investment from our parent company, Continental Diamond Tool Corporation, we have expanded our 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 our 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 we began producing in early 2023. As CDT Ltd. continues to evolve and adapt to the ever-changing technological landscape, we remain committed to delivering innovative solutions and superior products to meet the growing demands of our customers worldwide.

Mastering Precision: How Traverse Diamond Dressing Enhances Grinding Wheel Performance

Precision in manufacturing is the key to producing high-quality components across various industries, from automotive to aerospace, and even in everyday consumer products. One crucial aspect of achieving this precision is the performance of grinding wheels. In precision grinding operations, where the tolerances can be incredibly tight, grinding wheel performance is paramount. Enter the Traverse Diamond Dresser, a type of diamond rotary dresser that plays a pivotal role in ensuring that grinding wheels are in top form. In this blog post, we will delve into the world of Traverse Disc Dressers and explore how they enhance grinding wheel performance.

The Basics of Traverse Diamond Dressing

The Traverse Disc Dresser is an indispensable wheel profiling tool in the realm of precision grinding. Also referred to as Diamond Wheel Dressers, they are designed to dress and shape profile grinding wheels to maintain an optimal condition. The dressing process involves the removal of abrasive material from the grinding wheel's surface, which can become uneven, clogged, or worn over time due to the abrasive grinding process.

Here's how Traverse Disc Dressers work their magic:

1. Material Removal: These dressers feature a wide range of diamond sizes and grades to achieve the desired dressing condition. As the rotary diamond dresser traverses across the grinding wheel's surface, it precisely and efficiently removes small amounts of abrasive material. This effectively 'cleans' the wheel, restoring its cutting ability.

2. Wheel Truing: One primary function of Traverse Disc Dressers is truing the grinding wheel. Over time, grinding wheels can develop irregularities, affecting the precision of the grinding process. The dresser ensures that the wheel runs true and maintains a consistent, flat or cylindrical shape, depending on the application.

3. Form Dressing: In precision grinding, some applications require intricate shapes or profiles to be ground onto workpieces. Traverse Disc Dressers can be employed for form dressing, which shapes the grinding wheel to match specific profiles with utmost precision.

Achieving Superior Grinding Wheel Performance

Now that we understand the role of Traverse Disc Dressers let's explore how these wheel profiling tools enhance grinding wheel performance:

1. Consistency is Key: Precision grinding demands consistency. Traverse Diamond Dressing ensures that the grinding wheel profile remains uniform in shape, minimizing variations in the workpiece's finish and dimensions. This consistency is essential for meeting tight tolerances.

2. Optimized Material Removal: Dressing the wheel not only ensures precision but also optimizes material removal rates. It enhances the wheel's cutting ability, reducing heat generation and the risk of burning the workpiece—a common issue in precision grinding.

3. Reduced Scrap Rates: With a properly dressed grinding wheel, the likelihood of producing defective or out-of-spec parts is significantly reduced. This translates to lower scrap rates and higher yields, ultimately improving the bottom line.

4. Versatility: Traverse Disc Dressers are versatile tools suitable for various grinding applications. Whether you're grinding metals, ceramics, or other materials, these dressers can be adapted to meet your specific needs.

5. Flexibility: Change parts/profile shapes frequently?  Traverse Disc Dressers allow you to quickly and easily make profile changes or dress in completely new profiles without making grinding wheel changes, saving you down time for wheel change overs and/or roll changes.

Applications for Traverse Disc Dressers

Traverse Disc Dressers play a pivotal role in a multitude of precision-driven industries. These grinding wheel truers are essential for maintaining and shaping grinding wheels, ensuring that precision grinding processes yield consistent and accurate results. Here's a succinct overview of how key industries rely on Traverse Disc Dressers:

Automotive: Crucial for precision grinding in tasks like crankshaft and camshaft production, gear manufacturing, and engine component fabrication.

Aerospace: Used in grinding operations for aircraft components and jet engine parts, where precision is paramount.

Tool and Die Making: Maintains the sharpness and precision of cutting tools, including end mills, drill bits, and punches.

Medical Device Manufacturing: Ensures precision in the production of surgical instruments, orthopedic implants, and dental tools.

Bearings and Bearing Components: Shapes and maintains grinding wheels to ensure the accuracy of bearing components.

Cutting Tool Manufacturing: Essential for achieving precise tool geometries and cutting-edge profiles in tools like inserts and taps.

Oil and Gas: Involved in precision grinding for drilling equipment, pumps, and valves, vital in this sector.

Metalworking: Used in the production of gears, shafts, and machine components to meet precision requirements.

Die Casting and Foundry: Maintains and shapes grinding wheels to finish cast components with tight tolerances.

Renewable Energy: Supports precision grinding operations for components in renewable energy technologies like wind turbines and solar panels.

These industries rely on Traverse Disc Dressers for precision and consistency in their manufacturing processes, making them essential tools for achieving the highest levels of accuracy in precision grinding operations.

Types of Traverse Disc Dressers

Traverse Disc Dressers come in distinct types, each designed for specific applications. They can be made with a wide range of diamond sizes and grades, with CVD (chemical vapor deposition) stones, or a combination of the two, to achieve the desired dressing condition.

1. Electroplated: Electroplated Traverse Disc Dressers are known for their short lead times and open and aggressive structure allowing for high removal rates with similar performance at a lower cost.

2. Metal Bond: Metal bond Traverse Disc Dressers offer flexibility with a range of bond systems and abrasives to custom fit the application and provide a balance of durability and precision, making them suitable for a wide range of grinding operations.

3. Sintered: Sintered Traverse Disc Dressers offer exceptional durability and precision and are ideal for applications involving hard and abrasive materials with tight profile tolerances. 

4. Reverse Plated: Reverse Plated Traverse Disc dressers stand out due to their unique construction, which allows for unmatched precision and efficiency in shaping grinding wheels. They offer benefits such as reduced dressing time, extended wheel life, improved surface finish, and versatility, making them a valuable asset for industries requiring the highest levels of accuracy in their grinding operations.

It's worth noting that CDTUSA manufactures all types of traverse dressers except Reverse Plated, which will be added to our lineup next year. CDT Limited in Europe (previously Consort Precision Diamond) specializes in Reverse Plated, as well as the other types of diamond rotary dressers. When it comes to grinding wheel truers, our dedicated teams are ready to assist you. Feel free to reach out for a free quote, and let us help you achieve precision and excellence in your grinding operations.