With a wide choice of products offered by major grinding wheel manufacturers, selecting a grinding wheel for your business and project can be a challenge. Depending on the geometry and type of the material you are grinding, factors to consider include the type of abrasive, bond hardness of the wheel, and grit size. As proper wheel selection ensures that the required finished product quality is achieved, here is a brief guide to help you make an informed choice.

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Depending on the material being cut, there are three types of diamond abrasives commonly used: natural, synthetic, and metal-coated synthetic diamond. Although natural diamond is rarely used nowadays due to its high cost, it is an excellent choice for grinding glass, ceramic, composites, and carbide. Synthetic diamond, on the other hand, is typically used for grinding non-ferrous metals and is commonly used in finish and critical form applications like valves, cranks, and automotive cam grinding. The third type, metal-coated synthetic diamond, is also used for cutting non-ferrous metals. This type of diamond is created by coating the grain with nickel to enhance its grain-holding power and heat resistance.

In general, diamond abrasives offer excellent wear resistance and grit retention, making them suitable for semi-finish and rough processing of challenging-to-machine materials. These materials include stone, fireproof and semiconductor electronic materials, ferrite, ceramics, and glass. Additionally, diamond abrasives are commonly used for materials such as quartz, silicon, crystal, titanium alloys, and cemented carbide.

2. Choosing the Right Type of Bond

The bonding material used in grinding wheels is crucial for holding the abrasive grains together. There are four main bond options: electroplated, vitrified, resin, and metal. Resin bond diamond wheels have a wide range of applications, including centerless, off-hand, and both dry and wet grinding. They are particularly effective for cutting ceramics, cermet, carbide, semiconductors, ferrites, and glass.

On the other hand, metal bonds are commonly used for materials that are hard and brittle, such as sapphire, ceramics, glass, tile, and quartz. These grinding wheels are specifically designed for cutting highly abrasive materials and have a long lifespan.

Vitrified bonds are used for grinding ceramics, PCBN, and PCD tools. Vitrified diamond wheels are also ideal for fragile and tough materials such as silicon, sapphire, and heat-treated HSS materials. As a rule, vitrified and metal bonds are custom-ordered and more expensive.

The fourth variety, electroplated bonds are best for low abrasive grinding and form grinding of heat-resistant materials and ferrous automotive parts.

3. Choosing the Concentration?

The concentration of diamond in a diamond grinding wheel plays a pivotal role in determining its suitability for various applications. For instance, a C75 concentration, with 75% diamond grit, is typically well-suited for dry grinding tasks. The relatively lower concentration allows for efficient heat dissipation during dry grinding, preventing the diamond from overheating and losing its cutting effectiveness. This makes C75 ideal for applications where keeping the workpiece cool is crucial.

On the other hand, C100 concentration, with 100% diamond grit, is a versatile choice for general grinding on materials like carbide. Its balanced composition provides an excellent compromise between abrasive power and heat management, ensuring efficient stock removal while maintaining the diamond's longevity. Lastly, C125 concentration, with an even higher proportion of diamond grit, is reserved for high-production scenarios where aggressive cutting and maximum durability are essential. In such applications, like heavy-duty metalworking, C125 ensures extended wheel life and superior performance, making it an indispensable choice for industries requiring high-volume grinding

4. Look at the Grit Size

Grit size indicates the number of the smallest openings through which the abrasive grain will pass. For instance, a 50-grit-sized grain will pass through a sieve with 50 holes per inch.

Grains are generally divided into very fine (320 ' 1,000), fine (320 ' 240 ), medium (240 ' 150), and course (150 ' 60  ). Course sizes are used for snagging and billet conditioning in foundries and steel mills. Medium sizes are best suited for high stock removal and surface finishing. Fine-grain sizes are used for small-diameter and fine-finish grinding while very fine grits are best for lapping and polishing.

Summing Up 

When choosing a diamond grinding wheel for manufacturing, the main factors are the type of abrasive and bond, the grade of the wheel, and the grit size based on the material you are grinding. Other factors that affect choice include the wheel speed in operation, the amount of stock that needs to be removed, and grinding contact between the work material and the wheel. As each factor matters, taking all factors into account is the best way to optimize grinding performance. 

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Whether you are looking for general guidance or are ready to get a quote, we are dedicated to helping you find the right solution ' and if we can't provide the exact wheel you need, we will let you know. We hope you'll explore the ways our team can help your business stay ahead of the competition.

Safety

Do's and Don'ts of Portable Abrasive Cup Wheels

Portable resin bonded abrasive cup wheels (straight Type 6 and tapered Type 11) have been excellent grinding tools since the late 's. These wheels are very safe when used correctly. However, accidents have occurred because of misuse and abuse of this product.

Avoiding accidents begins with learning and following the basic Dos and Don'ts for portable abrasive cup wheels listed below.

Do's

• Do check all wheels for cracks or damage before use.
• Do check machine speed against established safe operating speed marked on the wheel.
• Do mount wheel on machine with speed at or below the wheel's rated speed.
• Do mount portable cup wheels only on grinders with proper retractable band-type (skirt) cup guards.
• Do mount threaded cup wheel with a proper backup flange of at least 1/3 the wheel's diameter.
• Do adjust proper cup guard so that it is between the operator and the wheel. Set the 'skirt' guard to within 1/8 inch of the cup wheel's rim (grinding surface).
• Do run wheel in protected area for one minute before grinding.
• Do clamp or secure all work-pieces before grinding.
• Do grind only on a cup wheel's rim.
• Do avoid bumping or striking the wheel onto any surface. Hard impacts can damage the wheel and cause it to break.
• Do feed the wheel into the work-piece at an even speed. Attempting to grind too fast will cause excessive strain on the wheel and may result in breakage.
• Do grind only materials designed for the cup wheel (e.g. metal, masonry, etc.).
• Do stop grinding and investigate any unusual sounds, vibrations, or anything that appears abnormal.
• Do keep hands and other body parts clear of the grinding wheel and spark stream.
• Do maintain your tools as if your life depends on it.
• Do replace damaged wheel guards.
• Do always handle and store grinding wheels in a careful manner.
• Do wear proper personal protection such as eye and face protection, apron, gloves, safety shoes, hearing protection, etc.
• Do shield bystanders and any flammable materials from the spark stream (shower).
• Do follow any symbols and warnings located on the wheel.
• Do review all applicable MSDS (Material Safety Data Sheets) before using a cup wheel.
• Do comply with ANSI B7.1, OSHA and all safety materials provided with the wheels and the tools.
• Do visit the abrasive manufacturer's website for additional safety information.
• Do contact your abrasive manufacturer if you have any safety questions.

Don'ts

• Don't use cup wheels on unguarded angle grinders or any machine that is not designed and marked for cup wheels.
• Don't exceed the speed marked on the cup wheel.
• Don't use spacers, washers, or hex nuts behind cup wheels. These items may aid in the removal of the wheel, but can lead to wheel breakages.
• Don't 'hang' the wheel below the cup guard.
• Don't use Type 27 (depressed center) or Type 28 (saucer-shaped) wheel guards with cup wheels because they are too shallow to offer full protection.
• Don't remove the 'skirt' or bottom of the cup guard.
• Don't alter a cup wheel. If the cup wheel does not fit on the tool, then get the correct tool or wheel.
• Don't use wheels that have been dropped or otherwise damaged.
• Don't use excessive downward pressure while grinding.
• Don't use on any machine NOT equipped with the proper cup guard.
• Don't grind wood or other non-approved materials with an abrasive cup wheel.
• Don't create a fire hazard. Shield any nearby flammable materials to prevent ignition from the spark stream (shower) or from latent sparks.
• Don't jam the wheel into the work.
• Don't allow the wheel to 'load up' with the material you are grinding.
• Don't grind on the side of a cup wheel.
• Don't strike the cup wheel onto the work-piece or any item as it may become damaged or break.
• Don't use this wheel if you have not reviewed all of the safety materials and have not been properly trained in the use of the tool and wheel.

For additional information on this topic or if you need any other abrasive safety information, please review the Norton Product Safety page, ANSI, OSHA and all literature provided by the abrasive wheel and machine manufacturer. You may contact the Saint-Gobain Product Safety Department at (508) 795-, fax: (508) 795-, or contact your Saint-Gobain Abrasives representative with any safety related questions.

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