CDT Ltd. Unveils £4m Expansion Creating 40 New Jobs

From left: CDT Ltd. Managing Director Jeff Wirth, Finance Manager Michaela Lawton, General Manager Troy Giacherio, Production Manager Justin Hughes, President of Sales Shane Vardaman, and Director Nick Viggiano stand outside the 30,000 sq. ft. factory that the North Wales operation will soon be occupying.

A fast-growing precision engineering firm has announced a £4 million expansion plan that will double the workforce at its North Wales operation by creating 40 new jobs and triple production.

The investment by the American owners of Continental Diamond Tool (CDT) will include moving to a 30,000 sq ft factory that’s nearly three times the size of its current premises in Kinmel Bay and is less than half a mile away on the Tir Llwyd Industrial Estate.

The move is being hailed by staff as the “perfect birthday present” for the North Wales operation which is celebrating its 40th anniversary this year, having been founded as Consort Precision Diamond in 1984, specialising in the manufacture of diamond-encrusted rotary dressers and grinding wheels.

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

Its 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 in Flintshire.

The firm was taken over and rebranded in 2018 by CDT which has its headquarters in New Haven, Indiana.

News of the investment was delivered by company President Nick Viggiano, during his visit to the Kinmel Bay site, along with Shane Vardaman, CDT’s President of Sales.

The bigger factory will enable the company to increase the range of products they make, adding several new types of high precision grinding wheels.

Nick Viggiano said: “Things have worked out even better than I thought and the investment is a real big vote of confidence in the workforce here because they have a similar work ethic  and there’s good camaraderie between everyone.

“We expect to be three times the size we are in a few years’ time because there is a very big market for the products we are going to bring over here. 

“We expect a swift ramp-up. Given our extensive expertise with these products in the States, we can help the team over here to quickly hit the ground running.

“The new building is like a blank canvas so we can set everything up exactly the way we want, so we’re very excited about it.”

It was as sentiment endorsed by the American Managing Director, Jeff Wirth, who said: “This investment has been a long time coming, with six years of preparation and teambuilding leading up to this moment.

“Our Kinmel Bay team, known for their rotary dressers, has already started producing electro-plated products on a small scale.

“Moving to the new building that’s nearly three times the size will give us the space to expedite that process. Additionally, we plan to manufacture two vitrified products and a hybrid product in the new space.

“This is a big step and it goes hand in hand with the expansion we’re doing in the United States.

“It comes down to Nick having a belief in the people and the team. This is going to put rocket boosters under the company to continue with the growth trajectory.

“With everything consolidated under one roof, we will get to lay it out to maximise efficiency instead of having to work around the nooks and crannies of the current building.

“The accommodation will also be improved for the employees with nice fresh locker rooms and a cafeteria.

“Nick has a supercharged, can do mentality and we expect to be up and running in the new building in the first quarter of next year.”

According to Finance Manager Michaela Lawton, the Kinmel Bay staff  were delighted to have the opportunity to finally meet Nick and Shane in person.

She said: “We have a solid leadership team here and a fantastic workforce that has the full backing of our American owners and it’s clear that the team here has proved itself worthy of this massive investment.

“It’s going to be a process over the next few years, with recruitment, upskilling and training and a lot of capital expenditure on fitting out the new factory with the specialist equipment that we need.

“We are aiming to follow in the footsteps of our American counterparts who have seen huge growth over the last 10 years.

“They’ve gone from our current size to employing over 200 people and we want to follow the same path.”

Justin Hughes, the production manager in Kinmel Bay, has worked at the Kinmel Bay site for 17 years and is the son of the retired technical director, Peter Hughes, who was among the founders of Consort Precision Diamond.

He said: “The takeover has been a marriage made in business heaven because the operations on both sides of the Atlantic dovetail perfectly with each other.

“The news about the investment is incredibly exciting and is the perfect birthday present as we celebrate our 40th anniversary.

“It will undoubtedly inspire us to reach even greater heights and become a truly global player. The sky really is the limit.”

---

Related articles:

Kinmel Bay firm to double workforce with £4m expansion - Rhyl Journal

Advanced manufacturer Continental Diamond Tool in new larger factory investment creating 40 jobs - MSN

---

Harnessing the Power of a Grinding Lab

When it comes to grinding, the first step in overcoming your challenges is gaining a clear, data-driven understanding of your process. Episode 2 of The Grinding Chronicles, hosted by CDT Application Engineer Harrison Sheldon, shows how using objective data from a grinding lab can significantly improve your process. Watch the video or read on to discover how CDT’s Grinding Lab can help you transition from subjective assessments to actionable insights.

The Grinding Chronicles - Episode 2

Making Sense of the Complex Grinding Process

Grinding is one of the most complex machining processes, involving more variables than most. Traditionally, operators have relied on their senses—sight, sound, and feel—to measure performance. While this may have worked in the past, it introduces subjectivity into the process. No two operators experience grinding in exactly the same way, leading to inconsistencies and inefficiencies. That’s where a grinding lab steps in, providing a more reliable and consistent way to measure performance.

Data-Driven Optimization

At CDT, we believe in using objective data to optimize grinding processes, and our Grinding Lab is at the forefront of this approach. The lab uses a variety of sensors to collect data across four key categories: cut, wear, quality, and cost. By focusing on these areas, we are able to make informed decisions that directly improve performance and efficiency.

Here’s how we break it down:

• Cut: The way a grinding wheel cuts is one of the most critical factors in overall performance. In our lab, we focus on three specific variables that help us understand how efficiently a wheel cuts: power, force, and vibration. Power is the energy input to the grinding process, while force reflects the mechanical effort required for material removal. Vibration is a crucial indicator of smoothness and stability in the grinding operation. By collecting data on these variables, we can ensure that the wheel is cutting at its optimal capacity.

• Wear: Wear is an inevitable part of any grinding process, but controlling and understanding it is essential for maximizing efficiency. In our Grinding Lab, we use precise measurement techniques to run the wheel through a test coupon, giving us an exact rate of wear. This data allows us to optimize wheel life, reducing the frequency of wheel changes and improving productivity.

• Quality: Quality is paramount in grinding, and factors like surface finish and burn must be closely monitored. Burn, for example, is a sign that the grinding process is too aggressive, potentially damaging the workpiece. By measuring surface finish and detecting burn, we ensure that the grinding process meets the high standards required by manufacturers without sacrificing quality.

• Cost: In any manufacturing process, cost is a key consideration. Our lab calculates the cost of running the grinding wheel under various conditions, allowing us to find the most cost-effective solution. Whether it’s reducing power consumption, minimizing wear, or improving quality, we aim to optimize processes to deliver the best possible performance at the lowest cost.

Optimizing Your Process

Once we have collected data from the four categories—cut, wear, quality, and cost—we begin the process of optimization. By adjusting key variables, such as wheel speed, we can examine how changes impact the overall performance of the grinding process.

For example, in a recent test we compared two different wheel speeds: 14 meters per second and 24 meters per second. At the higher speed, the system produced more energy, but this came at a cost—burn was observed on the surface of the workpiece. On the other hand, the slower speed resulted in no burn and delivered a smoother surface finish. By analyzing these results, we were able to determine that the slower speed was a better option for both quality and cost-efficiency in that specific scenario.

This is the true power of our data-driven approach. Rather than relying on guesswork or subjective measures, we generate detailed, actionable insights that allow us to make informed decisions. These insights help us to improve efficiency, extend tool life, and reduce operational costs for our customers.

Bringing the Lab to You

One of the unique advantages of CDT’s Grinding Lab is its portability. We understand that every production environment is different, and the conditions in a controlled lab might not perfectly reflect the realities of your facility. That’s why we offer the option to bring our Grinding Lab directly to your site.

Using portable sensors and equipment, we can set up quickly and begin collecting data on your production machines. In as little as an hour, we can install the sensors, return the machines to operation, and start gathering valuable data. This allows us to analyze your specific grinding process in real time, helping you make immediate improvements without needing to transport your equipment or materials to an offsite location.

Whether you are developing a new grinding process or optimizing an existing one, CDT’s portable Grinding Lab offers a fast and effective way to gain insight into your operations.

Why Use a Grinding Lab?

The value of using CDT’s Grinding Lab lies in the objective, reliable data it provides. Unlike subjective measures, which vary from one operator to another, data from the lab is consistent, accurate, and easy to analyze. This data allows us to make informed decisions that improve efficiency, reduce costs, and enhance quality.

By measuring key variables such as power, force, and vibration, we are able to identify areas where performance can be improved. This level of precision is simply not possible with traditional observation methods. The end result? A more efficient, cost-effective grinding process that delivers consistent, high-quality results.

Get in Touch

Are you ready to take the first step toward solving your grinding challenges? Let CDT’s Grinding Lab help you move beyond guesswork and into the world of data-driven optimization. Email us at thegrindingchronicles@cdtusa.net to find out how we can help you develop or optimize your grinding process.

Check out more episodes of The Grinding Chronicles on our YouTube channel, where we continue to explore innovative solutions to your grinding challenges.

And remember, at CDT, we believe in the power of data to drive performance. Be sure to hit like, follow, and subscribe to our channels to stay up to date on our latest insights and updates!

An Essential Guide to Grinding Process Optimization for Boosting Performance in Precision Manufacturing

To stay competitive in precision manufacturing, grinding operations require continuous improvement in performance and efficiency. Understanding the factors that influence grinding, such as speeds, feeds, and material removal rates, can significantly impact your results. In this comprehensive guide from Continental Diamond Tool, Product Engineer Thi Dang and Engineering Consultant Jon VanSant share their expertise as they unpack the essential elements of grinding process optimization. Episode 8 of The Grinding Chronicles offers valuable insights into maximizing Q-prime, balancing G ratios, and selecting the right grinding wheel speeds. Whether you’re looking to refine your current operations or upgrade to the latest in bond technology, our engineering team’s breakdown outlines the key factors you need to consider to enhance your grinding processes. Watch the video or read on to discover practical tips and advanced strategies for getting the most out of your grinding tools.

The Grinding Chronicles - Episode 8

Unlocking the Secrets to Optimizing Your Grinding Process

In this article, you will learn the essentials for optimizing your grinding process, focusing on the metrics that matter most for achieving peak performance. From understanding the basics of speeds and feeds to exploring advanced bond technology, this guide provides actionable insights for any precision manufacturing operation. Whether you're new in the field or looking to enhance your current practices, this informative article from The Grinding Chronicles team offers valuable knowledge to help you get ahead in the industry.

Understanding the Basic METRICS in GRINDING

One of the first considerations when optimizing a grinding process is understanding the basics—speeds, feeds, and material removal rates. These elements are fundamental to the grinding process and play a crucial role in determining the efficiency and quality of the finished product.

Speeds and Feeds:

Speeds refer to the rotational speed of the grinding wheel, typically measured in surface feet per minute (SFM). Feeds, on the other hand, relate to the rate at which the workpiece is fed into the grinding wheel. Together, these parameters influence the rate of material removal, surface finish, and the overall efficiency of the grinding process.

It's essential to understand that faster isn't always better. While higher speeds can increase material removal rates, they can also lead to increased wheel wear and the potential for thermal damage to the workpiece. Therefore, finding the optimal balance between speed and feed is key to maintaining both efficiency and quality.

Material Removal Rate (Q-prime):

Q-prime, or material removal rate, is a critical measure of grinding performance. It is calculated by multiplying the depth of cut by the feed rate, resulting in the amount of material removed per unit time. Higher Q-prime values typically indicate shorter cycle times, which can significantly enhance productivity.

However, achieving high Q-prime values requires careful consideration of other factors, such as wheel wear and the quality of the finished surface. A high Q-prime might reduce cycle times, but if it leads to excessive wheel wear or poor surface quality, the overall efficiency of the process may suffer. Thus, optimizing Q-prime involves balancing it with other critical parameters, such as the G ratio.

The G Ratio:

The G ratio is another vital metric in grinding. It is defined as the volume of material removed from the workpiece divided by the volume of wheel wear. A high G ratio indicates efficient grinding, where more material is removed with less wheel wear. However, similar to Q-prime, achieving an optimal G ratio requires balancing various factors.

Maximizing Q-prime WHILE Balancing the G Ratio

Maximizing Q-prime while maintaining a high G ratio is the key to optimizing grinding processes. To achieve this balance, it’s important to consider the following:

1. Wheel Speed: Higher wheel speeds can lead to increased wheel wear due to elevated temperatures. Therefore, it’s crucial to find an optimal speed that maximizes material removal without excessively wearing the grinding wheel.

2. Coolant Delivery: Proper coolant delivery is essential in controlling the temperature during grinding. Efficient coolant systems help dissipate heat, reducing thermal damage to the workpiece and wear on the grinding wheel. This, in turn, helps maintain a high G ratio.

3. Machine Stiffness and Power: The stiffness of the grinding machine and the power of the spindle also play significant roles. Machines with low power or poor stiffness may limit the achievable Q-prime and G ratio, restricting the overall efficiency of the grinding process.

By carefully considering these factors, manufacturers can optimize their grinding operations to achieve both high Q-prime and G ratios, leading to improved productivity and efficiency.

The Evolution of Bond Technology

Bond technology plays a critical role in the performance of grinding wheels, particularly in their ability to achieve high Q-prime and G ratios. The history of bond technology in grinding wheels is a testament to the continuous advancements that have been made in this field.

A Look Back:

In the 1960s, phenolic resin bonds were the standard, offering Q-prime values of around three. By the 1970s, the introduction of polyimide bonds pushed Q-prime values to around five. The year 2000 marked another leap with hybrid bonds, which increased Q-prime to approximately seven.

Today, we are capable of removing material at rates between 10 and 15, thanks to the latest advancements in bond technology. This evolution highlights the importance of continuously upgrading to the latest bond technology to stay competitive in the market.

Introducing CDT's EVO Hybrid Bond:

Continental Diamond Tool has been at the forefront of these advancements with its EVO Hybrid Bond. Released earlier this year, the EVO Hybrid Bond represents a significant step forward in bond technology, offering the ability to achieve Q-prime values over 10 without compromising the G ratio.

The development of the EVO Hybrid Bond was driven by the need for a bond system that could grind aggressively while minimizing wear and maintaining excellent corner retention. This bond was also designed with thermal conductivity in mind, to transfer heat away from the part and prevent damage to the diamond, which is sensitive to high temperatures. Learn more about CDT’s EVO Hybrid Bond product here.

Practical Tips for Optimizing Your Grinding Process

Now that we’ve covered the theoretical aspects of grinding optimization, let’s look at some practical tips that can help you apply this knowledge to your operations:

1. Evaluate Your Current Operations: Start by assessing your current grinding processes. Measure your Q-prime and G ratio to establish a baseline. Identify areas where improvements can be made, whether in speed, feed rate, or wheel selection.

2. Invest in the Latest Technology: Consider upgrading to the latest bond technology, such as CDT’s EVO Hybrid Bond. Newer bonds can significantly improve your material removal rates and reduce wheel wear, leading to better overall efficiency.

3. Optimize Coolant Delivery: Ensure that your coolant system is operating efficiently. Proper coolant delivery is essential for controlling temperatures and reducing thermal damage, which can extend the life of your grinding wheels and improve the quality of your finished products.

4. Regularly Maintain Equipment: Regular maintenance of your grinding machines is crucial. Ensure that your machines are running at optimal stiffness and power to maximize performance and avoid limitations in Q-prime and G ratios.

5. Train Your Team: Make sure your team is trained on the latest grinding techniques and technologies. A well-informed team can make better decisions on the shop floor, leading to improved productivity and efficiency. At Continental Diamond Tool, our application engineers are here to help. We regularly connect with our customers to fine-tune their equipment and train their operators on the optimized speeds and feed rates to use with our grinding wheels.

Optimizing grinding processes is essential for staying competitive in precision manufacturing. By understanding and balancing key factors like Q-prime, G ratio, and wheel speed, manufacturers can significantly enhance their grinding operations. Continental Diamond Tool’s latest advancements, including the EVO Hybrid Bond, provide valuable tools for achieving these goals. Whether you’re looking to improve your current processes or invest in new technologies, the insights provided in this guide offer a clear path to optimizing your grinding operations. Implement these strategies to ensure your manufacturing processes are both efficient and effective, helping you to stay ahead in a demanding industry.

Metal Bond Grinding Tools: Strong and Resilient

At Continental Diamond Tool (CDT), we take pride in the excellence of our Metal Bond grinding wheels and tools, designed for unmatched strength and resilience. Our commitment to product quality and customer service sets us apart in the industry. 

In this video and article below, you’ll get an inside look at our process and team. Learn why CDT has been a leader in custom Metal Bond grinding tool manufacturing for more than half a century. See inside our metal bond department and discover these reliable superabrasive solutions for industrial grinding of difficult materials such as carbide, ceramics, and glass.

Precision and Innovation in Metal Bond Grinding Wheel Manufacturing

Dedication to quality is evident in every step of our manufacturing process at Continental Diamond Tool. "CDT has invested heavily in the quality of our product over the years, improving the dimensional aspects of it and the performance of the product overall," explains Brian Yates, CDT Metal Bond Supervisor. We are dedicated to keeping pace with the latest technology to ever improve our products and processes. This commitment to quality ensures that our metal bond grinding wheels not only meet but exceed customer standards.

Lucas Tapp, a design engineer at CDT, further elaborates on the unique properties of our metal bond diamond wheels: "Metal bond is probably the hardest diamond tool that CDT manufactures. It's good at low RPMs and dissipates heat very quickly, which creates a better result for grinding." 

As grinding professionals know, adequate heat dissipation is crucial for maintaining the integrity of both the tool and the material being worked on. Excessive heat can cause burning, reduced workpiece quality, and shorter tool life. It is Metal Bond’s exceptional properties that have led our engineers to incorporate elements from this time-tested bond type into our innovative EVO Hybrid Bond line. This new line is breaking production records in the cutting tools industry, showcasing the enduring value and adaptability of Metal Bond technology.

About Metal Bond Diamond Tools

Metal bond grinding tools offer the long life and low maintenance that many precision manufacturing processes need to be competitive. Suitable for all levels of both wet and dry grinding, these wheels are built for endurance and performance. Metal bonded diamond tools are created from the sintering of powdered metals and other compounds with Diamond or Cubic Boron Nitride (CBN). These superabrasives held in a metallic bond produce an extremely strong product that holds its shape. 

Metal Bond wheels have the hardest matrix, performing best in operations under flood coolant. Because they have such a slow wear rate, metal bond wheels require less maintenance and downtime for dressing. Dressing is a process that removes material from the grinding wheel to release dull grit, expose new edges, and re-true its shape. Metal Bond’s hardness and long tool life makes it a favorite for many industries.

The Manufacturing Process

The creation of a custom metal bonded diamond grinding wheel is a meticulous process, involving several key steps to ensure precision and reliability. We start by machining the core to the customer’s precise specifications before custom molding the diamond abrasive with our graphite process. The diamond section is then sintered, where the powdered metals and abrasives are heated to temperatures of almost 2,000 degrees fahrenheit, causing them to coalesce and adhere to the core in a solid or porous mass. Once formed, the tool is machined again to tighter tolerances, then polished, balanced, marked, and shipped. 

In the video, Lucas shares a glimpse into the strengths of our manufacturing process: "We have state-of-the-art technology here at CDT that allows us to create a very precise, consistent product for our customers. When customers come to CDT, they're surprised by the cleanliness, our efficiency, and the amount of investment we've made in process innovation through automation and quality control systems.”

The Importance of Customer Service

At CDT, customer service is not just a department; it’s a commitment that is central to our culture. Brian Yates, our Metal Bond Supervisor, emphasizes this dedication: "Here at CDT, customer service is very important to us. I know personally that anytime a customer runs out of a tool, I will drop whatever I'm doing and get that product out as soon as possible." 

Our team understands the importance of timely delivery: our customers depend on it to maintain their operational efficiency. It’s our job to do everything in our power to deliver the tools they need when they need them.

Applications and Benefits

Metal bond tools are versatile and can be used in many applications. "Primarily, we recommend metal bond for grinding carbide, ceramics, and glass. We also make a rotary dresser that helps dress other grinding wheels," Lucas elaborates.

• Common Industry Applications: Metalworking, Cylindrical, Surface, Cutoff, Tool & Cutter, Core Drills, Hole Saws, Reamers, Dressing Disks, Custom Tools.

• Recommended Materials: Tungsten Carbide, Ceramics, Glass, Ferrites, Powdered Metals, Titanium Graphite Composite.

• OEM Machine Compatibility: DMG Mori, Makino, Rollomatic.

Metal bond diamond wheels are both durable and efficient, providing superior performance in demanding environments.

Customization and Expertise

Metal Bond is perhaps the best known bond material, thanks to its long history and overall utility. Continental Diamond Tool has been manufacturing Metal Bond diamond tools and metal bonded diamond grinding wheels since 1973. 

At CDT production of each tool is tailored according to our customer’s specific dimensions and abrasive requirements. The product is custom designed to the application and the industry. To select the best bond and abrasive type, we look at a variety of characteristics, including material, grinding machine, dressing method, volume of parts, coolant type, stock removal, and current grinding process. Through customization, we improve the efficiency and enhance the productivity of our customers.

"Our products undergo rigorous testing and numerous quality checks to ensure that each CDT tool is tailored to the customer’s needs,” explains Lucas Tapp. CDT’s product warranty guarantees that every tool we manufacture must meet or exceed our customer’s past experience based on the quality or lifespan of their current tooling, or we will only charge according to its value, based upon their current tooling cost.*

We are proud of our half a century in building metal bonded diamond tools. Our team continuously strives to innovate and improve our products to meet the evolving needs of our customers.

Extending the Life of Metal Bond Grinding Tools

To extend the lifespan of your metal bond grinding tools, we suggest these helpful tips:

• Use the correct type and size of grinding wheel for your material and application.

• Employ proper coolant to prevent overheating.

• Clean and maintain the tool with dressing as part of your process to remove dust and debris and expose new diamond crystals. 

• Store the tools in a dry, clean place to prevent moisture or any chemical exposure.

• Conduct regular inspections for signs of wear, damage, or malfunction.

By following these guidelines, Continental Diamond Tool's Metal Bond grinding products will deliver exceptional performance for a very long time.

Delivering Excellence

At Continental Diamond Tool, our metal bond team is dedicated to delivering the strongest and most resilient metal bond grinding wheels with unmatched durability, performance, and customer satisfaction. Click here to explore our full range of superabrasive solutions custom designed for precision grinding applications and discover why CDT is a trusted name in the industry.

CNC Machining vs. Traditional Machining: A Comparative Analysis for Precision Grinding Tools

When it comes to the manufacture of high-precision grinding wheels in diamond or cBN (Cubic Boron Nitride), the choice of machining method can significantly impact the quality and efficiency of production. At Continental Diamond Tool (CDT), we leverage traditional machining, CNC (Computer Numerical Control) machining, and automated robotic CNC machining to deliver high-precision grinding tools for many global industries. Having a skilled workforce and modernized equipment in all three types of machining is a distinct advantage for us and our customers. 

In this article, we will compare the pros and cons of these machining methods. You’ll learn how we incorporate all three into our manufacturing process to get the highest quality and most cost-effective results for our grinding tools and wheels. Finally, we will share insights from our machinists about what it takes to excel in these roles and contribute to the production of superior precision tooling.

Machining Methods: Pros and Cons

Traditional Machining

Advantages:

• Flexibility: Traditional machining is highly adaptable for a wide range of tasks and can be used for both simple and complex geometries without the need for extensive programming.

• Human Expertise: Skilled machinists can make real-time adjustments based on their experience and intuition, which can be beneficial for unique or custom jobs.

• Lower Initial Cost: The initial investment for traditional machining equipment is generally lower than that for CNC machines, making it more common in low-volume or smaller operations.

Challenges:

• Lower Precision: Traditional machining typically relies on manual control, which can lead to variations in precision and consistency, particularly with high-volume orders.

• Slower Production: Manual operations can be time-consuming, reducing overall productivity compared to automated processes.

• Higher Labor Costs: Skilled machinists are required to operate traditional machines, which can equate to higher labor costs over time.

CNC Machining

Advantages:

• High Precision and Consistency: CNC machining offers unparalleled precision and repeatability, which is crucial for manufacturing high-quality grinding tools like electroplated diamond and resin bond grinding wheels.

• Increased Efficiency: Computerized control allows for faster production cycles, reducing lead times and increasing throughput.

• Reduced Labor Costs: Once programmed, CNC machines require less manual intervention, reducing the need for highly skilled labor for routine operations.

Challenges:

• Higher Initial Investment: The cost of CNC machines and the necessary software can be significantly higher than traditional machining equipment.

• Programming Requirements: CNC machining requires specialized programming knowledge, which can be a barrier for some operations.

• Maintenance and Repairs: CNC machines can be more complex to maintain and repair, requiring specialized technicians.

Automated Robotic Machining

Advantages:

• Enhanced Productivity: Automated CNC grinding uses robotic arms that can operate continuously with minimal supervision, significantly increasing production rates and efficiency for producing grinding wheel components.

• Consistency and Quality: Automation ensures that every grinding tool in a series is machined to the exact same specifications, reducing the likelihood of defects and ensuring uniform quality.

• Labor Optimization: Automation frees human workers to focus on more complex and value-added tasks, optimizing labor utilization and reducing repetitive strain injuries.

Challenges:

• High Upfront Costs: Integrating automation involves significant initial investment in both equipment and software, which can be a barrier for smaller companies.

• Technical Complexity: Automation systems require a high level of technical expertise to implement and maintain, which can pose challenges for operations without such capabilities.

• Adaptability: Automated systems can be less flexible than manual operations when it comes to handling custom or unique jobs that require careful planning and programming.

How Machining Fits in CDT's Manufacturing Process

At CDT, machining plays a crucial role in the manufacturing process of our superabrasive products. Whether using resin, metal, vitrified, or hybrid bonds — or our sophisticated electroplating process — precision machining ensures our grinding tools meet the stringent requirements of our customers.

Resin, Metal, Vitrified, and Hybrid Bonds

• Initial Machining: Depending on the tool, CNC machining sometimes occurs before the molding and sintering processes to prepare the core elements.

• Post-Sintering Machining: After molding and sintering, additional CNC machining and manual grinding fine-tune the precision of the finished grinding wheel within customer tolerances.

Plating Process

• Initial Machining: All machining is completed at the beginning, where the desired wheel size and geometry are typically CNC-machined onto a steel core or blank. 

• Minimal Finishing: Once electroplated, minimal finishing is required as the plating process closely mimics the core geometry, allowing for the programming of complex shapes and geometries with minimal additional work.

High Volume Orders

• Initial Machining: With high-volume repeat orders, we utilize automated robotic CNC machining to prepare the core or blank. These systems can run 24/7 to stockpile common wheel sizes.

• Finishing: Every order, large and small, goes through final finishing/machining and several quality checks to ensure that each grinding tool meets our stringent quality standards. This meticulous process guarantees that all products, from vitrified grinding wheels to metal bond diamond tools, adhere to the precise specifications and tolerances required by our customers.

Examples of Machinist Roles at CDT

CNC Operator

The CNC operator at CDT is responsible for programming, setting up, and operating CNC lathes or mills. This role is essential for producing high-precision grinding tools, from electroplated grinding tools to vitrified and resin bond grinding wheels.

• Key Responsibilities:

• Programming CNC machines for various tasks.

• Setting up CNC lathes or mills for production runs.

• Operating CNC machines to produce precision grinding tools.

• Skills and Qualities:

• A passion for learning and problem-solving.

• Logical thinking and attention to detail.

• Willingness to be trained on new technologies.

"To be a good fit as a CNC machinist, you need to enjoy the challenge of looking at a problem and solving it logically. One of the great things here at CDT is if you have limited experience or no experience, we are willing to train." — Ron Fuller, Lead Operator

How to apply >

Manual Lathe Operator

The manual lathe operator at CDT typically works in the metal bond department but sometimes with others as well, handling tasks that require manual precision and expertise. This role can come into play at the beginning, middle, or end of the production process, especially for metal bond diamond tools. 

• Key Responsibilities:

• Operating manual lathes to produce grinding tools.

• Ensuring quality and precision through manual adjustments.

• Overseeing the product quality through all manufacturing stages.

• Skills and Qualities:

• High motivation and a readiness to “get your hands dirty.”

• Reliability and willingness to work overtime on occasion.

• Appreciation for quality, taking pride in your work, and seeing the product evolve.

"What I like about working in the metal bond department is seeing the product go through the process and the steps, and then ending up with the finishing piece. It's satisfying to see that through." — Brian Yates, Supervisor

How to apply >

The CDT Machining Edge

At CDT, we understand the importance of choosing the right machining method to meet the demands of precision grinding tool production. By leveraging traditional machining, CNC machining, and automated CNC grinding, we can offer our customers high-quality diamond grinding wheels, vitrified grinding wheels, electroplated diamond grinding wheels, resin bond grinding wheels, and other superabrasive tools with exceptional precision and efficiency. Each method has its advantages and challenges, and our integrated approach allows us to optimize production based on the specific needs of each project.

As technology continues to evolve, we are committed to adopting the best practices and innovations to deliver the highest standards in the industry. If you are interested in joining our team, apply today at cdtusa.net/careers.

How to Diagnose Surface Pattern Problems in Grinding

Many precision grinding operations require impeccable surface finishes for both function and aesthetics. Addressing surface pattern problems is vital for ensuring the quality of the final product, eliminating waste, and controlling costs. In this detailed overview, we expand on the insights provided by Paul Christy, Senior Product Engineer at Continental Diamond Tool, as he explains how to troubleshoot and fix common causes of surface patterns. In Episode 7 of The Grinding Chronicles, Paul covers the complexities of surface patterns caused by various types of vibrations, runout, and servo system instability. Watch Paul’s video or read on to learn more about identifying and addressing these issues to optimize your grinding operations.

The Grinding Chronicles - Episode 7

Surface Pattern Troubleshooting Guide

Surface pattern problems in grinding can significantly impact the quality and precision of your workpieces. Diagnosing and resolving these issues requires a deep understanding of the underlying causes and appropriate troubleshooting techniques. This article explores common causes of surface patterns in grinding and provides expert insights into their diagnosis and elimination.

Self-Excited Vibration

One of the primary causes of surface pattern problems is self-excited vibration, which occurs at the natural frequency of the machine system. This type of vibration indicates that some component within the machine—such as the spindle, the part, or the dresser—is being excited. The resulting oscillating pattern is called chatter. Notably, this vibration only manifests when the grinding wheel and the workpiece (or the wheel and the dresser) are in contact.

Self-excited vibration results from a lack of sufficient component stiffness. The key to mitigating this issue lies in increasing the machine's stability, which requires a greater machine stiffness compared to the process stiffness. There are three main process variables that can be adjusted to help eliminate self-excited vibration:

1. Velocity of the Workpiece: Lowering the workpiece's speed can reduce process stiffness.

2. Velocity of the Grinding Wheel: Decreasing the grinding wheel's speed similarly lessens process stiffness.

3. Width of Contact: Reducing the contact width between the grinding wheel and the workpiece can also help.

By strategically lowering one or more of these variables, you can effectively diminish the impact of self-excited vibration.

Forced Vibration

Forced vibration occurs at a frequency corresponding to a driving force within or outside the machine. Common examples of such driving forces include unbalanced rotating bodies and pump pulsations. This type of vibration can often be diagnosed using a process of elimination. By sequentially turning on and off all rotating bodies within the machine, you can identify the source of the vibration when it ceases upon the deactivation of a specific component.

Runout

Runout is a prevalent issue in grinding due to the inherent imperfections of rotating components. It occurs when the outer surface of a rotating component does not maintain perfect concentricity with its axis or center line. Specifically, runout in a traversing diamond roll can create a pattern in the grinding wheel, which is then transferred to the workpiece. This pattern typically manifests as angled parallel lines, known as Barber Pole or Roping Patterns.

To address surface patterns caused by runout, it is essential to identify the optimal dresser and wheel RPMs. Varying the diamond roll speed during dressing can reduce the likelihood of pattern formation on the grinding wheel, preventing its transfer to the workpiece. Another effective solution is lapping the diamond roll to the machine's spindle bearings, thereby eliminating runout.

Servo System Instability

Servo system instability is another potential source of surface patterns on workpieces. The servo system controls the movement accuracy of machine components, using digital feedback to ensure precise positioning. Mechanical decoupling within components such as ball nuts, couplings, bearing support units, or scale mountings can create discord within the servo system. This results in oscillations as the system struggles to determine the correct position, leading to surface patterns on the workpiece.

Solving servo system instability typically requires sophisticated instrumentation and physics-based analysis. Iterative process changes alone are unlikely to resolve this complex issue.

Key Takeaways in Mastering Surface Finish

Diagnosing and fixing surface pattern problems in grinding necessitates a thorough understanding of the potential causes and their specific remedies. Whether dealing with self-excited vibration, forced vibration, runout, or servo system instability, targeted adjustments and precise troubleshooting are essential for maintaining the quality and precision of your grinding operations.

For more detailed information and expert guidance, refer to Episode 7 of The Grinding Chronicles, where Paul Christy shows specific measures you can take to diagnose and eliminate surface pattern problems. If you are experiencing surface patterns similar to those discussed in this article and require further assistance, do not hesitate to contact the Continental Diamond Tool engineering team at TheGrindingChronicles@cdtusa.net.

Understanding and addressing these grinding challenges will enhance your operational efficiency and ensure the superior quality of your manufactured products.

CDT Is Boosting Capacity of Plated Grinding Wheels and Dressing Tools

An electroplated grinding wheel completes machining on CDT’s new PUMA DNT 2600LM CNC Lathe.

At Continental Diamond Tool, we invest in cutting-edge technology, skilled professionals, and continuous improvement. We aim to be the world’s most reliable source for innovative, high-quality, customized precision grinding solutions, offering exceptional performance and long life. The market has responded, and the last several years we have experienced tremendous growth.

To meet growing demand, our manufacturing center in North Wales has recently acquired three new pieces of equipment, made possible in part by the Conwy – UK Shared Prosperity Grant. This strategic investment is set to significantly expand our production capabilities for the manufacture of electroplated grinding wheels and diamond rotary dressers.

The Journey of Investment

In Q3 2023, CDT Ltd. in the United Kingdom embarked on an ambitious venture with the introduction of a new product line at its facility: custom-engineered electroplated cBN and diamond grinding wheels and tools. To support this initiative, we purchased dedicated electroplating tanks, stripping lines, and specialized manufacturing equipment for product testing and prototyping. This setup has been essential in ensuring that these products maintain the same precision and quality customers expect from CDT.

Meanwhile, our Rotary Diamond Dressers line — the specialty of this business center — continues to thrive. Sharing machining equipment between this booming line and the growing orders for electroplated products has become a challenge. Additionally, we are starting to see strain in our inspection capacity with the increased demand for these two technologies.

Strategic Acquisitions for Expanding Production

The introduction of a Puma lathe, OGP SmartScope, and Doosan milling machine addresses these challenges and paves the way for sustainable growth, diversification, and more efficient delivery for our customers.

1. Puma DNT 2600LM CNC Lathe

   The first new equipment delivery took place in May with the arrival of the Puma DNT 2600LM CNC Lathe. This piece of equipment is crucial to meet the increasing demand for electroplated products independently from our rotary diamond dressers. Having a dedicated Puma Lathe for plated products assists in the timely delivery of these high-quality tools to our customers without compromise.

2. OGP SmartScope

   In June we received the OGP SmartScope, a revolutionary 3-axis video measurement system. The SmartScope E7, with its IntelliCentric™ fixed lens optical system, 6-megapixel camera, and 5-position digital zoom, delivers high-resolution images that are essential for precise metrology. This state-of-the-art equipment will expand our inspection capacity to maintain the high standards expected of our precision products.

3. Doosan Milling Machine

   Delivered in early September, the Doosan Milling Machine completes our trio of new equipment purchased with the government grant. This addition further bolsters production, ensuring we have the capacity to meet growing demands and continue our commitment to excellence.

A CNC operator programs CDT’s new PUMA Lathe that was delivered and installed in May.

A CDT quality tech measures a coupon on the new OGP SmartScope that was delivered in June.

A technician operates CDT's Doosan Milling Machine that was delivered in September.

Impact and Future Prospects

With the Puma Lathe, OGP SmartScope, and Doosan Milling Machine now up and running, we are already seeing the benefits in our production processes. The ability to utilize these machines for Plated products independently of our Rotary Diamond Dressers line has optimized our workflow and improved our overall efficiency.

These investments also support a long term strategy for CDT Ltd. They not only address our current production challenges but also set the stage for future growth and diversification at this facility. As we continue to innovate and expand our capabilities, we remain committed to the timely delivery of the high-quality products our clients expect.

Stay tuned for more updates as we continue to enhance our production capabilities and explore new horizons in the industry.

---

For more information on the Puma DNT 2600LM CNC Lathe, visit here.

Continental Diamond Tool Ltd., located in Kinmel Bay on the Western Coast of North Wales in the United Kingdom, is dedicated to providing top-tier superabrasive products for precision grinding and dressing.

---

At Continental Diamond Tool, we are excited about these investments and look forward to leveraging this equipment to further our mission of excellence in the industry. If you need a solutions provider for your precision grinding applications, please contact our sales team through our website contact form or
call +44 1745-343951 (UK) / 1-800-443-6629 (USA).

A Breakdown of the 4 Common Bond Systems in High Precision Grinding

If precision grinding is a critical component of your manufacturing process, understanding the bond system of your grinding wheel will help you in maintaining operational efficiency and product quality. In this detailed overview, we will explore the four most common bond systems used in superabrasive grinding wheels: Resin, Metal, Vitrified, and Electroplated. Continental Diamond Tool Engineering Manager Jeff Wirth breaks down the components of these bond systems, discussing their composition, manufacturing processes, and ideal applications in Episode 6 of The Grinding Chronicles. Watch Jeff’s video or read on to learn more about selecting the right bond to optimize your grinding operations.

The Grinding Chronicles - Episode 6

Understanding the Four Common Bond Systems

Resin Bonds

Resin bonds are plastic-based compounds typically made from phenolics or polyimides. These bonds are versatile and can be enhanced with fillers such as copper or silicon carbide to improve performance. The manufacturing process for resin bonds at CDT begins with creating a tailored formulation that includes the bond material, abrasive, and fillers. This dry powder mixture is blended in special tumblers and then carefully and uniformly packed into mold cavities. The molds undergo hot pressing, where temperature and pressure are meticulously controlled to achieve the desired density. Finally, the wheels are finished by machining and grinding them to the specified size and geometry.

Properties and Applications:

• Tough and Durable: Resin bonds are fully dense and easy to use, making them suitable for a variety of grinding applications.

• Versatile: They can work with nearly any material, from hard metals to softer alloys.

• Enhanced Performance: Fillers like copper or silicon carbide can be added to improve heat dissipation and grinding efficiency.

• Wide Range of Applications: Suitable for diverse grinding tasks, including tool and cutter grinding, centerless grinding, and surface grinding.

Metal Bonds

Metal bonds can be composed of various metals, including bronze, copper, and iron, and may sometimes be alloyed with precious metals like silver. Metal bonds are known for their hardness, toughness, and durability, making them ideal for grinding highly abrasive materials such as glass and ceramics. Although metal bonds grind more slowly than other types, they offer the longest lifespan. The manufacturing process for metal bonds at CDT is similar to that of resin bonds, involving formulation, mixing, molding, hot pressing, and finishing.

Properties and Applications:

• Hardest and Toughest: Metal bonds are the most challenging to use but provide superior durability.

• Long-Lasting: They offer the longest lifespan among bond types, reducing the frequency of wheel changes.

• Ideal for Abrasive Materials: Best suited for grinding materials like glass, ceramics, and carbide.

• Durability: Excellent for applications requiring extreme durability and extended wheel life, such as in the automotive and aerospace industries.

Vitrified Bonds

Vitrified bonds are made from glass or ceramic materials, creating a porous structure that significantly reduces grinding force. This allows for higher grinding speeds, making vitrified bonds ideal for high-production applications. These bonds offer moderate to high material removal rates and excellent form accuracy, as they can be dressed and profiled in-process using rotary dressers. The manufacturing process for vitrified wheels at CDT involves formulation, mixing, cold pressing, and a sintering (baking) process to fuse the glass or ceramic together. The final step is finishing, similar to the other bond types.

Properties and Applications:

• Porous Structure: Lowers grinding force and allows increased speeds, enhancing efficiency.

• High Production: Ideal for high-production applications such as automotive part manufacturing.

• Moderate to High Material Removal Rates: Efficient for large-scale operations, balancing speed and precision.

• High Form Accuracy: Can be dressed and profiled in-process using rotary dressers, making them suitable for precise and consistent grinding tasks.

Electroplated Bonds

Electroplated (or plated) bonds consist of a single layer of abrasive held by a nickel-based metal bond. The process begins with machining the desired wheel size and geometry onto a steel wheel core. The non-plated surfaces are masked to prevent unwanted plating. The wheel core is then placed in a bath with a nickel-based solution and the abrasive material. By applying a positive charge on one side and a negative charge on the other, nickel plating is deposited onto the wheel core, causing a single layer of abrasive to adhere. Excess abrasive is removed, and the plating process continues until the abrasive layer is encapsulated to the desired level, typically 50-100% depending on the application. Electroplated products are suitable for complex geometries and low to medium production applications due to their high material removal rates and fast grinding speeds.

Properties and Applications:

• High Material Removal Rates: Provides the fastest grinding speeds, ideal for rapid material removal.

• Cost-Effective: Single layer of abrasive can be stripped and replated, extending the wheel’s life.

• Ideal for Complex Geometries: Precise form replication with minimal finishing, suitable for intricate designs.

• Low to Medium Production: Suitable for specific applications requiring detailed shapes and efficient material removal.

Key Considerations for Selecting the Right Bond System:

Choosing the appropriate bond system for your grinding application is crucial for achieving optimal performance and quality. Each bond type offers unique properties and advantages, making them suitable for different materials and grinding conditions. By understanding the composition, manufacturing processes, and ideal applications of Resin, Metal, Vitrified, and Electroplated bonds, you can make informed decisions to enhance your grinding operations.

Factors in Bond System Selection:

1. Material to be Ground: The hardness and abrasiveness of the material significantly influence the choice of bond.

2. Grinding Speed and Efficiency: Consider whether the application requires high-speed grinding or if longevity and durability are more critical.

3. Application Specifics: Determine if the grinding operation involves complex geometries or requires high form accuracy.

4. Production Volume: High-production environments may benefit from vitrified bonds, while electroplated bonds are ideal for low to medium production with intricate details.

If you have any questions or want to learn more about which bond type would work best for your application, please reach out to our application engineers at TheGrindingChronicles@CDTUSA.net. For more industry insights and expert advice, check out these articles or watch our playlist for The Grinding Chronicles on YouTube. By leveraging the right bond system and understanding its properties, you can significantly improve your grinding efficiency, product quality, and operational cost-effectiveness.

Essential Role of Diamond Rotary Dressers in Precision Grinding

Grinding wheels, essential for precision manufacturing and shaping of materials, inevitably wear down with use. This wear occurs due to the abrasive action against hard materials, causing gradual degradation of the wheel’s surface. Over time, the cutting edges of the abrasive particles dull, and the bond holding these particles in place can break down, leading to a loss of material from the wheel. This wear not only reduces grinding efficiency but also affects the accuracy and finish of the ground parts.

"Every grinding wheel, whether it be conventional or superabrasive, requires dressing to maintain its profile and cutting performance. Rotary Diamond Dressers are especially useful for precision applications, when you're trying to achieve micron-level tolerances," explains Ed Pitock, Production Manager for Rotary Diamond Dressers.

The Best tool for Grinding Wheel maintenance

Types of Diamond Rotary Dressers

There are two primary types of diamond rotary dressers, also called diamond rolls:

• Traverse-Style Diamond Rolls: Move across the grinding wheel, providing a comprehensive dressing solution. Often a single traverse-style dresser can be programmed for use with many different profiles.

• Plunge-Style Diamond Rolls: Plunge directly into the grinding wheel, offering uniform dressing of a single precise profile for a specific application.

At Continental Diamond Tool, we custom design both types for our customers to meet the requirements of their processes, machines, and part specifications. This ensures that the desired surface finish and geometry are consistently achieved.

Bond Structures

The bond structure in Diamond Rotary Dressers refers to the material and method used to hold the abrasive diamond particles in place. The bond structure determines the strength, durability, and performance characteristics of the dresser. There are different types of bond structures, each suited for specific applications:

• Infiltrated Bond Structure: Also known as sintered, this structure involves filling the spaces between diamond particles with a powdered metal that is then sintered. It is known for its robustness and longevity, making it suitable for demanding applications.

• Reverse Plated Bond Structure: In this method, diamond particles are electroplated with a layer of nickel. While not as durable as infiltrated bonds, reverse plated bonds allow for more complex geometries and are used for specialized applications.

CVD Inserts

In the context of Diamond Rotary Dressers, CVDs refer to Chemical Vapor Deposition diamonds. These synthetic diamonds are created in a controlled environment, allowing for the production of high-purity and high-quality diamond material. Advantages include:

• Purity: CVD diamonds have fewer impurities compared to natural diamonds, resulting in reliable and predictable performance.

• Consistency: The controlled manufacturing process ensures uniformity and consistency in diamond quality for reliable results.

• Customization: The CVD process allows for the production of diamonds with specific properties that are advantageous to industrial applications. This material can also be cut into specific sizes and shapes for reinforcing of a high wear areas or used as the main lot abrasive in the roll.

CVD diamonds are sometimes added to Diamond Rotary Dressers due to their unique properties, including exceptional hardness, wear resistance, and thermal conductivity. By incorporating CVD diamonds, rotary diamond dressers become a powerhouse in micron-scale precision, superior durability, and enhanced efficiency, making them ideal for highly demanding dressing applications.

Industrial Applications

Diamond Rotary Dressers are utilized across various industries, offering precise solutions for different needs. Key sectors include:

• Automotive: These dressers ensure that automotive components meet stringent tolerance requirements, contributing to the reliability and performance of vehicles.

• Aerospace: The precision of Diamond Rotary Dressers is critical for producing aerospace components capable of withstanding extreme conditions.

• Cutting Tools: These dressers maintain the sharpness and efficiency of cutting tools, enhancing their performance and longevity.

• Bearings: Precision dressing is essential for producing high-quality bearings that meet the rigorous demands of various applications.

By maintaining critical dimensions, enhancing longevity and sharpness, and providing smooth and flawless surfaces, Diamond Rotary Dressers play a vital role in supporting these key industries.

Quality and Customization in Manufacturing

The quality and custom design of Diamond Rotary Dressers are paramount to their effectiveness. "When customers visit our Indiana facility here, they're blown away," notes Troy Giacherio, Product Manager for Rotary Diamond Dressers. "They're going to see the attention to detail, the quality that's taken in every step of the process, and the meticulous customization that we do."

Each product is designed specifically for the customer's process, machine, and part, ensuring a precise fit and optimal performance. This level of customization ensures that the unique needs of each customer are met, providing the ideal solution to their grinding processes.

Customer Support and Technical Expertise

At Continental Diamond Tool, customers also benefit from our extensive support and technical expertise. In 1984, Consort Precision Diamond Company set out to build a reputation as the finest maker of the emerging Diamond Rotary Dresser technology. 

Fast-forward 40 years, under Continental Diamond Tool’s leadership, these advancements have been added to the mix at its 200,000 sq. ft. manufacturing center in the United States. Combining the British ingenuity with CDT’s 50 years of excellence in superabrasive grinding wheels, CDT has solidified its position as a leader in offering this cutting-edge solution for precision manufacturing.

Our Diamond Rotary Dresser departments span two continents and have decades of combined experience. Our team is readily available to assist with any challenges, ensuring that customers receive tailored solutions and guidance. "Here at CDT, our customers can always rely on our experience, our technical expertise, and our customer service," Giacherio emphasizes.

An Essential in Advanced Manufacturing

Diamond Rotary Dressers provide essential solutions for maintaining the efficiency and precision of grinding wheels across multiple industries. With robust bond structures, customization options, and applications in sectors like automotive, aerospace, cutting tools, and bearings, these tools are critical for achieving high-precision outcomes. Continuous investment in advanced technology and quality assurance ensures that Diamond Rotary Dressers from Continental Diamond Tool meet and often exceed customer expectations. By utilizing the latest advancements in superabrasives and precision engineering, these tools address the evolving needs of various industries in their precision manufacturing processes.

Brian VanHall Hired as CEO of Continental Diamond Tool

New Haven, Indiana – May 31, 2024 – Continental Diamond Tool is delighted to announce the hiring of Brian VanHall as the Chief Executive Officer, starting June 3, 2024. Founded in 1973, Continental Diamond Tool is a global leader in the design, manufacture, and application of precision grinding products for a multitude of industries.

Brian VanHall has been hired as the Chief Executive Officer at Continental Diamond Tool, starting June 3, 2024

As CEO of Continental Diamond Tool, Mr. VanHall is excited to advance the company's mission of delivering high-quality, custom-engineered tooling solutions to customers around the world. “I am honored to be entrusted by the Viggiano family and CDT team to help grow the legacy of excellence in developing and delivering innovative solutions for advanced manufacturing applications” said VanHall. 

Mr. VanHall previously served as Executive Vice President with Ambassador Enterprises. With over 20 years of executive experience, Mr. VanHall brings a record of leading innovative projects, transformative programs, and strategic partnerships for multinational organizations to grow economic value, organizational effectiveness, and social impact. Brian received his Master of Business Administration (MBA) from Baylor University and holds graduate certifications in organizational leadership, corporate governance, strategic planning, and project management. 

Nick Viggiano, President of Continental Diamond Tool, said, “We are excited to welcome Brian VanHall to the team and look forward to a future of continued excellence and growth with his leadership.”

For more information about our management team at Continental Diamond Tool, click here.

About Continental Diamond Tool Corporation:

Established in 1973, Continental Diamond Tool Corporation (CDT) is a premier manufacturer of precision tooling solutions for industries worldwide. With a legacy of technical expertise and innovation, CDT is renowned for its custom superabrasive grinding wheels and diamond dressing tools. CDT is also North America’s exclusive source for Krebs & Riedel conventional abrasive wheels, which are custom profiled at our facility. Headquartered in New Haven, Indiana, CDT operates a state-of-the-art 200,000 sq. ft. manufacturing center dedicated to delivering high-quality products and exceptional customer service. Learn more >

Recognizing the Importance of Cleaning and Maintenance at Continental Diamond Tool

In manufacturing, the spotlight often shines on the experienced engineering team, the cutting-edge machinery, and the high precision grinding products we produce. Yet, behind the scenes, two critical forces work tirelessly to ensure that everything operates smoothly: the cleaning and maintenance crews. At Continental Diamond Tool, we recognize the indispensable role these teams play in our daily operations and overall success.

Keeping Operations Running Smoothly

The primary role of cleaning and maintenance is to ensure that all equipment and facilities are in top working condition. In the manufacturing process, even minor disruptions can lead to significant delays and costs.

Dan Becker, Maintenance Supervisor, details the meticulous care his team puts into preserving operational efficiency: "We maintain all of the manufacturing equipment in the building. For example, we manage the coolant in 5 dozen CNC machines and routinely clear out all of the chips. We also have 12 grinders, which we take completely apart, clean out, and inspect the belts and pulleys for wear regularly." This is just a snapshot of the thoroughness with which they maintain operations.

Regular maintenance and thorough cleaning prevent machinery breakdowns, allowing operations to continue without interruption. These efforts are crucial for ensuring that our orders are delivered on time. In this way, our cleaning and maintenance teams ultimately contribute to customer satisfaction. Timely delivery is a priority our customers rely on.

Ensuring Safety and Quality Standards

Quality and safety are also top of mind at Continental Diamond Tool, and our cleaning and maintenance crews are key players in both of these areas.

Maintaining a safe working environment starts with cleanliness. By regularly removing debris, cleaning spills, and ensuring that all areas are free from hazards, our cleaning techs help prevent accidents and injuries. Likewise, well-maintained facilities and equipment are essential for operational efficiency. Their diligent work supports our commitment to providing a safe workplace for all employees.

Quality requires precision. In the manufacturing of our high-quality diamond tools, this means that even the smallest particles can impact the final product. Our cleaning crew works tirelessly to maintain a contaminant-free environment, directly influencing the quality and reliability of our products. This meticulous attention to detail ensures that we meet and exceed industry standards and customer expectations.

"At CDT, we like to keep a clean shop. To do this job well, you have to be on your feet a lot and always stay moving, stay motivated. It requires attention-to-detail and focus," says Boston Stopher, Cleaning Tech at CDT. Hear more from Boston in this video:

Enhancing Efficiency and Employee Morale

A clean and well-maintained environment not only extends the life of our equipment and enhances the quality of our products and service, but it also boosts overall efficiency and morale. Workers are able to perform their tasks more effectively in an orderly setting. Furthermore, regular maintenance can improve the performance of machinery, potentially increasing output and reducing energy consumption. A clean and well-organized workplace also boosts employee satisfaction and pride in their work environment. With tidiness comes increased productivity and a stronger sense of team overall.

Cleaning: A Pathway to Growth

Our cleaning department is made up of 8 to 10 dedicated individuals who manage the cleanliness of our soon-to-be 200,000 sq. ft. manufacturing space between our 1st and 3rd production shifts. Key responsibilities include:

• Sweeping and mopping floors

• Wiping down equipment

• Disposing of trash and metal shavings

Many team members start their careers in this department right out of high school, gaining valuable insights into the workings of different departments and shaping their future career paths within the company. For those interested in exploring opportunities as a cleaning technician, more information is available on our careers page.

Maintenance: Proactive Problem Solvers

Our maintenance department, though small, is mighty, comprising just 4 individuals with 68 years of combined experience. They are responsible for maintaining more than 500 plating tanks, 60 CNC machines, plus numerous other pieces of equipment small and large. The efficiency of our processes, reliability of our products, and comfort and safety of our facilities hinge on the efforts of this team. As Maintenance Specialists, these professionals play a pivotal role in our seamless operations. Their tasks include:

• Routine maintenance

• Basic and minor repairs

• Changing filters, coolant, and fluids

• Some fabrication work

• Collaboration with engineering and manufacturing teams on projects

This dynamic team is committed to upholding our high-quality and safety standards, keeping our state-of-the-art equipment in top-notch condition, and contributing to the overall growth of Continental Diamond Tool. Find information about our Maintenance Specialist role and other positions at CDT here.

Conclusion

At Continental Diamond Tool, we understand that our achievements are not solely the result of the sophisticated equipment we use or the exceptional products we create; they are also a testament to the dedication and hard work of various departments that frequently go unrecognized. Our cleaning and maintenance crews are vital to our operation, and their contributions are valued as an integral part of our success. By supporting their efforts, we reinforce the foundation of our company’s strength and ensure that we continue to lead in the industry with integrity and excellence.

How to Dress a Vitrified CBN Grinding Wheel with a Diamond Rotary Dresser

If you work in manufacturing, particularly in the specialized area of precision grinding, it cannot be overstated the importance of wheel dressing to maintain operational efficiency and product quality. In this comprehensive guide, we will look at the best techniques for traverse dressing a vitrified cubic boron nitride (CBN) wheel using Rotary Diamond Dressers. In Episode 5 of The Grinding Chronicles, CDT Product Manager Troy Giacherio details the specific parameters and most important factors necessary for achieving peak performance in dressing and truing operations. Watch Troy’s video or read on to learn more.

The Grinding Chronicles - Episode 5

Best Techniques for Success When Dressing a Grinding Wheel

Before plunging into the specifics of dressing a Vitrified CBN wheel, it's imperative to understand the dichotomy between two fundamental processes: truing and dressing. Truing involves sculpting the shape or profile of the grinding wheel, while dressing focuses on sharpening the wheel and removing accumulated debris. While diamond rotary dressers serve both functions, understanding this distinction facilitates the implementation of effective dressing strategies.

Essential Parameters for Dressing Success

There are four key parameters to measure for optimizing the dressing of a grinding wheel:

• Velocity Ratio At the heart of dressing lies the velocity ratio, calculated by dividing the velocity of the diamond roll by the velocity of the grinding wheel. This parameter holds significant importance in dressing operations. For Vitrified CBN wheels, the recommended velocity ratio stands at 0.8. Maintaining this ratio ensures that the diamond roll adeptly removes the bond material, laying bare fresh abrasives for optimal grinding performance.

  Overlap Ratio The overlap ratio describes the velocity at which the diamond dresser traverses the wheel's face to sculpt its profile and hone its edge. For Vitrified Bond CBN wheels, an overlap ratio ranging between 2 to 4 is ideal. Sustaining a steady pace ensures a seamless traversal across the grinding wheel. It is important to prevent the dresser from dwelling in any single spot to guarantee uniform dressing proficiency.

  Depth of Dress The depth of dress measures the extent to which the diamond roll plunges into the grinding wheel, thereby dictating the volume of material extracted per pass. When it comes to Vitrified CBN wheels, we recommend a precise depth of dress set at 0.0002 inches per pass. Adherence to this specification not only optimizes grinding efficiency and minimizes downtime, particularly in high-volume production environments, but also preserves the longevity of the grinding wheel, yielding an optimized return on investment.

  Dress Interval The dress interval is defined as the frequency at which the grinding wheel needs dressing, and it is closely tied to the application at hand. Unlike their conventional abrasive counterparts, Vitrified CBN wheels do not require frequent dressing. On the contrary, it is not uncommon to grind hundreds of parts between each dressing session. However, it is important to remain vigilant. Keep an eye on the process and be prepared to adjust the dress interval if part quality diminishes.

When Should I Dress My Grinding Wheel?

Dressing frequency varies depending on several factors specific to your process. Here are two key indicators to monitor in order to assess grinding efficacy and determine when it's time to dress your grinding wheel.

• Power Draw The power draw during grinding operations can be a reliable indicator for grinding wheel dressing. A drop in power draw signals that the wheel is cutting freely, with utmost efficiency, while an uptick in power suggests a looming need for dressing. Neglecting timely dressing can lead to issues such as burn or unwanted variations in surface finish. That’s why it is important to keep a close eye on power draw dynamics to prevent such issues.

• Surface Finish The surface finish of machined parts relies heavily on consistently high levels of grinding performance. A well dressed wheel produces exceptional surface finishes characterized by minimal variations and unyielding consistency in part quality and dimensional accuracy. Therefore, regular dressing sessions conducted with meticulous technique are essential for maintaining superb parts quality and excellence.

Troubleshooting and Optimization

If you are still experiencing issues such as finish patterns or burn despite adhering to prescribed dressing parameters, it may be time to call in the assistance of an expert. Companies like Continental Diamond Tool have application engineers who are trained to analyze grinding processes, pinpoint underlying issues, and facilitate optimization for enhanced performance. Armed with a portable grinding lab, these experts bring their expertise on-site to meticulously evaluate coolant delivery systems, fine-tune machine settings, and traverse a gamut of other variables to resolve persistent challenges. With their help, you can galvanize productivity to unprecedented heights. If you would like help with your wheel dressing or grinding process, don't hesitate to reach out to our engineering team at TheGrindingChronicles@CDTUSA.net.

Mastering Wheel Dressing

Proper dressing of a Vitrified CBN grinding wheel with a Diamond Rotary Dresser is the key to optimal grinding performance and part quality. By incorporating the parameters and techniques we’ve outlined in this article, manufacturers can achieve reductions in downtime, extension of wheel life, and unwavering consistency in high quality results. 

Additionally, by closely watching power draw and surface finish, you will know when it is time to dress before problems get out of hand. With consistent dressing, and seeking expert help when needed, companies can overcome grinding challenges and greatly improve productivity.

Whether transitioning from conventional abrasives to CBN or seeking to refine existing grinding processes, mastering proper dressing techniques with Diamond Rotary Dressers holds the key to consistent and dependable success. Check out more grinding related topics in other episodes of The Grinding Chronicles from Continental Diamond Tool.

Continental Diamond Tool Enters Strategic Partnership with Krebs & Riedel

New Haven, Indiana – April 30, 2024 – Continental Diamond Tool Corporation (CDT) proudly announces its partnership with Krebs & Riedel, a global leader in the abrasives industry. This collaboration positions CDT as the exclusive North American source for Krebs & Riedel abrasive products within the USA, Canada, and Mexico.

Nick Viggiano, President of Continental Diamond Tool (left), and Florian Riedel, Managing Director of Krebs & Riedel.

Erik Van Meter, Senior Product Manager of Conventional Abrasives at Continental Diamond Tool and Krebs & Riedel’s official representative, expresses enthusiasm about the new partnership, stating, "We are thrilled about the high-quality products Krebs & Riedel will bring to the table. They are a well-respected name in conventional grinding wheels and have products for many industrial grinding markets which include automotive, aerospace, gear and medical."

The collaboration between CDT and Krebs & Riedel signifies a partnership deeply rooted in a shared commitment to excellence. For more than half a century, Continental Diamond Tool Corporation has consistently delivered technically superior precision grinding products across a variety of industries. As a thriving second-generation family business, CDT’s commitment to innovation and quality is reflected in its state-of-the-art North American manufacturing facility, which is undergoing a sizable expansion to cater to new product development and meet diverse customer needs. With this and a growing subsidiary in the United Kingdom, it has solidified its status as a premier worldwide manufacturer of custom superabrasive grinding wheels and diamond dressing tools. 

Similarly, Krebs & Riedel is a family-owned enterprise headquartered in Bad Karlshafen, Germany, since 1885. It has a proud century-long legacy in providing quality abrasive products globally. With over 30 distributors and subsidiaries, K&R's dedication to customer satisfaction aligns seamlessly with CDT's founding principles. This partnership promises cutting-edge solutions and unwavering commitment to superior products and customer service in the abrasive products landscape. In this strategic move, CDT and Krebs & Riedel are poised to tackle the most critical tooling requirements of a growing market of customers.

“This partnership marks an exciting chapter for Continental Diamond Tool Corporation as we join forces with Krebs & Riedel to expand our product offerings in North America,” said Nick Viggiano, President of CDT. “We are proud to align with Krebs & Riedel's esteemed reputation and look forward to delivering exceptional abrasive products and unparalleled service to our customers across the continent and beyond.”

“With CDT we have found the partner who complements our high-performance products with superior service. From the first meeting we felt the same level of professionality and passion for grinding. I am convinced that our customers in North America will feel the same,” said Florian Riedel, Managing Director of Krebs & Riedel. 

For more information about Continental Diamond Tool Corporation and its comprehensive range of precision grinding products, including those from Krebs & Riedel, please visit www.cdtusa.net/products.

Continental Diamond Tool Corporate Office in New Haven, Indiana, USA

About Continental Diamond Tool Corporation:

Established in 1973, Continental Diamond Tool Corporation (CDT) is a premier manufacturer of precision tooling solutions for a variety of global industries. With a legacy of technical expertise and innovation, CDT is renowned for its custom superabrasive grinding wheels and diamond dressing tools. Headquartered in New Haven, Indiana, CDT operates from a state-of-the-art 200,000 sq. ft. manufacturing facility dedicated to delivering high-quality products and exceptional customer service.

Krebs & Riedel Head Office in Bad Karlshafen, Germany

About Krebs & Riedel:

Family owned since its start in 1885, Krebs & Riedel (K&R) has been a prominent global player in the abrasive products industry. With a vast network of over 30 distributors, subsidiaries, sales companies, and representatives worldwide, Krebs & Riedel is renowned for its quality abrasive products and commitment to customer satisfaction.

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.