We are introducing a new diamond grinding wheel series to the market. We have done the research and have developed a supreme product for grinding alloys, inconel, and PCD. Our DX Series is a great solution to your grinding needs, especially for high volume, short cycle-time jobs. This series performs beautifully when flooded with coolant, and run at high in-feed rates, the crystal that we use is a lover of material removal. This crystal has an aggressive cutting structure when fractured. We recommend in-feeding at 0.3 Q-Prime as a great starting point with our DX Series. If you are seeing loading or material smear you might want to possibly in-feed faster. The reason for loading could possibly be too light of a chip load. When a chip isn’t large enough for the crystal used, evacuation becomes an issues due to the chip being smaller than the crystal keeping it in the porous cavity and under-cut from the crystal.
Diamond Grinding Speeds and Feeds
6,500 to 9,000 SFPM, Depth Of Cut 0.100″ @0.625″ width, In-Feed 3″ to 10″ per minute. This is a great place to start when running our mandrels. We recommend starting with these speeds and feeds. Now, we recommend contacting us for review our your operation prior to making drastic changes in speeds and feeds. Typically we can help point you in the right direction when it comes to inputs for your operation when it comes to feeds and speeds. If you are looking for more information, please contact us.
Typical Diamond Grinding Applications
Cylindrical Grinding or Centerless Grinding (D2, M2, M4, 8620, Inconel, Carbide, PCD, Hard Alloys)
Surface Grinding or Plate Grinding AKA Blanchard
ID Grinding or Bore Grinding (Carbide or PCD) (We recommend a 1A8 Style Head For This Style Grinding)
Diamond Crystal Types
We have multiple different suppliers that we use for raw Diamond and CBN. We find that certain suppliers carry crystal that works better for certain application. This diversification allows us to use the best crystal on the market for your tooling. By not being biased in the procurement side, we find that our product reaches the hands of the best, because we started with the best. One of our suppliers, World Wide SuperAbrasives Inc. has supplied us for years. We find that using their products on Carbide Applications has proven out to be the best. There are hundreds of different crystals on the market, with that kind of selection and diversity in characteristics, our Diamond Grinding Wheels perform to the highest standard due to being custom tailored for your application. Also, in the last decade quite a bit has changed in the world of post processed diamonds. When I say, Post Process, I do not mean used up diamonds, I mean post being sorted depending on characteristics, then put through another process to help their performance. In many cases, coating these crystals with a thermal spray coating, or encasing them in a high stress metal coating with help retain crystal shape, sharpness, and form. With the introduction of this type of post process, the options for variety of crystal to try on an application are almost endless. Let our in-house research and field research let us direct you on what crystal type to use. We want your Diamond Grinding Wheels to be the best they can be (Army Pun!)
Diamond Tooling On Sale
It’s a special week here at Diamond Plated Mandrels Inc. we are happy to announce a sale on all our SX and SX 150 Line of Diamond Plated Tooling this week only. Sept. 28th thru Oct. 5th. With the new launch of our website diamondplatedmandrel.com , we are selling all our SX and SX 150 Jig Grinding and ID Grinding Mandrels for 50% off. With grit sizes ranging from 40 mesh to 1200 mesh, we have the capabilities to plate to meet your surface finish standards. We use a wide variety of Diamond Crystal Types when manufacturing our mandrels. Our SX series is a Highly Friabile crystal specifically designed for ID grinding for D2, High Tungsten Alloys, Carbide, PCD. We want micro-fracturing in our diamonds to help keep a sharp cutting edge. Keeping the crystal sharp helps reduce heat during the grinding process. This will help increase overall tool life and prevent any loading causing cycle time delays. Ordering from us today would mean, you get 50% off a high-quality extremely long tool-life reducing your CPU greatly. Contact us today to get a quote on our SX and SX150 line of Diamond Tools. We do offer discounts for quantity breaks, that works with the 50% sales as well.
How To Know If You Need Diamond Tooling For Your Operation
Often when grinding HSS, you find that using a diamond crystal instead of a CBN helps with overall grind characteristics and tool life. Typically these applications are Jig Grinding 8620 or 48 HRC harder steels with low coolant application to the grind. This is due to the nature of the diamond tooling compared to cubic boron nitride. Diamond Tooling handles heat and heavier chip loads than CBN, this allows the crystal to handle the stress of the cut without prematurely breaking down causing inconsistent grinds and short tool life.
Diamond Tooling vs. Borazon
As I mentioned above, there is quite a bit of difference between Diamond and CBN tooling, with the main difference being the thermal conductivity of the crystal structure itself. With Diamond Tooling handling upwards of 2,100 Degrees Fahrenheit in a cut without breaking down, with CBN and Silicon Carbide breaking down in the 1,600-1,800 degree range. With the stress capabilities of the Diamond Tooling, allowing for higher spindle speeds and faster in-feeds in your operations. Now, this will have a negative impact on tool life, as you are increasing chip load unless you are increasing SFPM by over 40%. Often times when ID Grinding an extremely hard material like D2 or M2, slow your in-feed and increase your spindle speed of SFPM. This will greatly reduce the load on your crystal cutting edge, this will help retain a sharp tool, and create a more consistent part blueprint.
Contact Diamond Plated Mandrels Inc. Today
Contact us today for a free application evaluation and quote. We want to supply you with the best diamond tooling that you have ever used. We put very high expectations on ourselves to produce tooling that goes above and beyond. As soon as you contact us, we will start the process of evaluating the best diamond tooling for you to use during your application. If you have high volume jobs, we can to CPU and estimated tool life estimates based on the amount of stock removal and SFPM capabilities of the machine.
Last week was a big week for us here at DPM.com, we developed a new tool for Rough Grinding Carbide. After extensive research and testing, we found that using a crystal with high friability, in a tough bond that was heat tolerant allowed us to retain “sharp” crystal. Many times when mandrel grinding Carbide, there is an issue with temperature due to the closed-off nature of the hole. Limiting air or hindering chip evacuation. This inherent issue with mandrel or jig work is limited workspace. This limited work space means the tool must remove the maximum amount of material without creating much heat. Using a crystal that is as large as possible, and still able to provide the desired finish is optimal. This can take a considerable amount of knowledge or experience working with formulation and mandrel manufacturing.
Carbide Grinding With Diamond Mandrels
Working with Carbide can be a fickle creature. Something about the structure that is carbide that delicately plays with strength to tension to stress. Here at DPM.com, we test all our mandrels and various crystal formulations internally on a variety of different materials. Mainly Carbide though. After extensive testing, we have released the SMKP Line of Abrasives into our portfolio. This has given us an advantage on the market, with tools that are showing extended life of up to 75%. This is all due to correct crystal sourcing for the application. Reduced cycle times, and extended tool lives provides our customers with a low cost per unit production providing a lucrative production environment. This is critical to long term survival in a saturated brutal market that is Carbide Grinding.
New Nickel Flashing Procedure
Over the last three months we have focused our efforts internally at our tanks to be able to provide a superior flashing that will hold under the harshest of environments. We performed over 3,300 different combinations and formulations until we were happy with the results. Now these tests were under some extreme situations, but we want our tooling to hold up to your worst environment. That’s why we test tooling at speeds and feeds that are not typical in the field. With spindles running at over 50,000RPM, we are truly punishing these tools, and we want them to fail when we are testing. This gives us the opportunity to optimize that tool, preventing the same issue from happening in the future, as well as, improving other aspects of the tools performance.