Diamond grinding wheels utilize synthetic diamond grit suspended in a resin, vitrified, or metal bond structure. Most often used in precision grinding applications where high material removal rates and dimensional accuracy are required, diamond wheels are employed by a range of industries including aerospace, medical, automotive, and electronics.
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So, why are diamond wheels such a popular choice? Let’s investigate the five main benefits of using a diamond grinding wheel.
- Exceptional Hardness
Diamond wheels are incredibly hard and wear-resistant, making them ideal for grinding other hard materials such as carbide. This feature also allows diamond wheels to withstand high material removal rates and provide better longevity when compared to conventional abrasive wheels.
- Superior Grinding Performance From rough grinding at high feed rates to cutting brittle materials with high
accuracy, the composition of a diamond grinding wheel can be manipulated to serve a multitude of applications.
This diversity stems from the combination of grit size and the concentration (or volume) of diamond grit present in the wheel’s bond. If finer grit is used, a higher quantity of grit particles can be included in the wheel bond. If larger grit is used, not as many grit particles will be able to fit into the wheel bond.
Fine grit is useful for high precision and works well with brittle materials, while coarse grit is ideal for faster material removal.
- Low Heat Generation
The bond structure of a diamond abrasive wheel does impact its heat-resistant
abilities. Resin bonds, for example, generate the least heat overall during grinding and are typically used for softer materials like ceramics and composites. Known as a more “flexible” bond, resin bonds have a faster-paced grit renewal rate than metal or vitrified bonds. This allows for a consistent, sharp cutting surface.
Slightly less heat efficient, metal bonds are typically used for grinding tougher
materials and are much harder than resin bonds. By retaining grit particles for longer, this bond allows the form of the wheel to hold its shape for extended periods.
Vitrified bonds are made of ceramic material, ideal for heat dissipation. They are typically suggested for grinding materials with low thermal conductivity.
Regardless of the bond structure, using a diamond grinding wheel reduces the
risk of heat damage to both the wheel and the workpiece. Synthetic diamond abrasive is highly conductive and chemically inert. This makes it a great material for heat dissipation.
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Similar to other machines, grinding wheels will wear down with use and as time goes on. This leads to poor part quality and surface finishes. Instead of replacing your grinding wheel, you can use a process referred to as "dressing" to restore the wheel to its former glory. Dressing a grinding wheel is the key to maximizing the performance and longevity of your tool. In this blog, we will discuss what dressing is, the benefits, and the types of tools to use.
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What is Dressing?
If you have noticed your grinding wheel is producing parts with inconsistencies then it may be time to dress your wheel. Dressing is used to remove grains, clogs, and excess bonding material from the wheel in order to return to its original surface finish and sharpness. In addition, dressing is also used to help restore the wheel's shape which changes with wear.
Types of Dressing and Tools
When it comes to dressing, there are two main methods: truing and standard dressing. Truing is performed at the time of installation. Truing can straighten the wheel and form it into its desired shape. On the other hand, standard dressing is used throughout the grinding process. Standard dressing is typically performed on an as-needed basis depending on the amount of material being removed, surface finish requirements and the accuracy required.
Now that you know the methods of dressing, let's discuss the types of tools you can use. What you use to dress your grinding wheel is dependent on the required cycle time as well as whether it needs to be trued or dressed. Here are the three main types:
Diamonds, the precious stones known for their shine and elegance, actually make great dressing tools. Diamonds are durable and hard which allows them to score and reshape dressing wheels very quickly. Diamond dressers come in single-point, multi-point, and other types depending on the job.
Grinding wheels are critical for achieving precise finishes, so they need to be maintained.
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Rotary Dresser
Rotary dressers are a high precision grinding tool that is used most often for profiling the wheels. Many high-tech industries that manufacture and produce high precision machine parts use rotary dressers. Since rotary dressers can be tied into already existing grinding machine controls, they are a great option for use with centerless, ID, OD, and double-disc grinders.
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Dressing Stones and Sticks
Dressing stones are used for profiling, dressing, and sharpening grinding wheels. These stones are typically made of aluminum oxide or silicon carbide which is why they're abrasive and suitable for this application. Aluminum oxide dressing sticks are another great option as well. Aluminum oxide tools are often used to dress tools that are made from diamond. Due to their aforementioned properties, diamonds are easily sharpened with aluminum oxide.
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Benefits of Dressing a Grinding Wheel