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DX Series Diamond Grinding Wheels

By | September 28th, 2016|Categories: Diamond Grinding Wheels|

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!)

50% Off Premier Diamond Tooling

By | September 28th, 2016|Categories: Diamond Plating, Jig Grinding, Jig Grinding Mandrels|Tags: , , |

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.

Rough Grinding Carbide

By | September 16th, 2016|Categories: Diamond Grinding Wheels, Jig Grinding, Jig Grinding Mandrels|Tags: , , |

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.

An Inside look at CNC Manufacturing

By | January 7th, 2017|Categories: Jig Grinding Mandrels|Tags: , , |

For more information on CNC Machining refer to: CNC Art Machining

An Inside overall look at CNC Manufacturing

Most individuals you speak to in your life will never have even read of the term CNC machining before. Little do they know that the CNC process has in all probability touched there everyday living in one way or another. If you work in manufacturing it is more likely that you have read of the term and you’ll most likely be dealing with a CNC at some point. Almost everything that an operator is able to do with classic machine tools is programmable with a CNC machine. Next we take a closer look at CNC machines and their functions.

The purpose why CNC machining tools are so profitable is due to there accuracy, performance and efficiency. A CNC machine is rather easy to keep up and running upon initial setup. Even the work piece loading method has been automated in some providers. Most of the time CNC operators are demanded to complete other assignments similar to the operations of the CNC. Some of these tasks include things like measuring work pieces and producing modifications to keep the CNC machine operating at maximum general performance.

If a CNC could move a work piece in 2 directions its performance would be seriously limited. This is why virtually all CNC machines are programmed to operate in several other ways. The actual CNC machine type contains to do with its programmable equipment as well. Some of these accessories include the following. An automatic tool changer allows the tool to be quickly placed in the spindle when machining. The speed of the spindle can easily be specified and the spindle can be turned in two directions. In addition many machining functions must have coolant for lubrication purposes.

With CNC touching so many aspects of manufacturing and massive fabrication. We now take a look at how CNC machining impacts the world of metal removal and steel fabrication. When getting rid of metal the procedures of facing, boring, turning, grooving, knurling, and threading are carried out with CNC turning centers. There are many variations of these machines which include things like, CNC milling machines, CNC drill and tap centers, and CNC lathes. Outside diameter grinding and internal diameter grinding would be completed on CNC grinders.

Every time using a CNC machine in association to metal fabrication, think some of these include; ultrasonic welding, laser cutting, welding, forming, material cutting, routing, riction stir welding, plasma cutting, and even sawing.

An Inside appearance at CNC Machining

By | January 7th, 2017|Categories: Uncategorized|Tags: , , |

For more information on CNC Machining refer to: Wikipedia CNC Machining

An Inside overall look at CNC Manufacturing

Most individuals you discuss to in your life will never have even listened to of the term CNC machining before. Very little do they understand that the CNC method has probably touched there daily life in one way or another. If you work in creating it is more likely that you have heard of the phrase and you’ll most likely be dealing with a CNC at some position. Almost everything that an operator is able to do with standard machine tools is programmable with a CNC system. Subsequent we take a closer look at CNC machines and their functions.

The reason why CNC machining tools are so profitable is due to there accuracy, effectiveness and efficiency. A CNC machine is rather easy to keep up and running upon initial setup. Even the work piece loading technique has been computerized in some companies. Most of the time CNC operators are required to complete other tasks equivalent to the functions of the CNC. Some of this kind of tasks include measuring work pieces and making modifications to keep the CNC machine running at maximum efficiency.

If a CNC could move a work piece in two directions its overall performance would be seriously limited. This is why just about all CNC machines are programmed to work in several other ways. The actual CNC machine type has to do with its programmable equipment as well. Some of these add-ons include the following. An automated tool changer will allow the tool to be mechanically placed in the spindle when machining. The rate of the spindle can quickly be specified and the spindle can be turned in two directions. In addition countless machining functions must have coolant for lubrication reasons.

With CNC touching so countless details of manufacturing and huge fabrication. We now take a look at how CNC machining impacts the world of metal elimination and steel fabrication. When eliminating metal the processes of facing, boring, turning, grooving, knurling, and threading are completed with CNC turning centers. There are many differences of these machines which include things like, CNC milling machines, CNC drill and tap centers, and CNC lathes. Outside diameter grinding and internal diameter grinding would be completed on CNC grinders.

Every time using a CNC machine in association to metal fabrication, think some of these include; ultrasonic welding, laser cutting, welding, forming, material cutting, routing, riction stir welding, plasma cutting, and even sawing.

The Evolution of CNC Machining

By | November 15th, 2016|Categories: Jig Grinding|

Many years ago, machining, metalworking and fabrication were performed by NC or numerical controlled. These Numerical Controlled machines were the brain child of the late John T. Parsons, whom was commissioned to work closely with the Massachusetts Institute of Technology, the end product was commissioned by U.S.A. Air Force.  With Aerospace parts and mechanisms being of intricate design and complex shapes. They were looking to find the cheapest Cost Per Unit method to manufacturing these parts. NC based machines became the industry standard of machining highly complex parts.

Computer Aided Design and Computer Aided Machining was developed in 1972, this made the room for prominent developments in CNC machining. By 1989, CNC machines became the industry standard. They were utilizing the ability to 3-D model and translate into production based manufacturing.

Originally, old numerical controlled machines had punch cards to operate. These codes were punched in a particular order to help logic based order machining. These codes were called G-codes. The codes were intended to give the machine positioning information and instructions. G –codes in Modern day CNC machines, with logical commands have been created to help build new programming languages by using existing coding as a platform. Some of the new coding is called parametric programming, this allows operators to make changes during machining and project loads, giving the ability to free create at the machine interface without having to stop and reflash to the new program.

The advantage of CNC machining is productivity, error reduction, accuracy, cost reduction, and safety. Operators and Inspection personnel involvement decreased when using a CNC machine. This greatly improves the Profit Margins or reduction of costs associated to the manufacturing.  With the involvement of CNC and the ability to run without an operator, some companies are utilizing lights-out production meaning they run the machines when no one is the facility to monitor production.  If there is a problem with the machine, the software automatically stops the machine and calls the operator or stops production until someone approves continued production.

In-Feed and Diameter

By | September 26th, 2016|Categories: Diamond Grinding Wheels, ID Grinding, Jig Grinding, Jig Grinding Mandrels|Tags: , , |

Over the last 80 years that grinding has become a very documented and researched manufacturing method, it has grown quite popularly with ID or Boring Grinding. Using a relationship between spindle speed, tool diameter, and crystal size/chip depth. Typical jog grinding happens with a spindle speed around 10,000-50,000 RPM; however, with technology advancements, we are seeing spindle speeds capable of 120,000+ RPMs. This has allowed jig grinding to gain some ground, being able to run your tools at much higher spindle rpms and SFPM, allows for higher in-feed rates, reducing overall cycle time for the operation.

When running a DPM Mandrel, we recommend a SFPM of around 7,500, with in-feeds around 3-8″ Per Minute. Depth of cut, somewhere in the 0.100″ range depending on the P-Line or Surface contact on the tool. We recommend per 0.25″ of contact, reduce infeed by 0.010″ This is due to tool pressure and deflection. If the user has a very stiff shank and large crystal sizes, they can run in-feed and depth outside this range. Our Jig Grinding mandrels are capable of sizes from .0080” to 20.000”. Our mandrel size is limited by our tanks. We do have partners that can plate over a 20″ piece.

Now, these speeds and feeds that were listed above are general in-feeds for HSS with a 40-60 Grit Mesh. Running Diamond on Carbide or PCD is a different story. We recommend running the same Surface Foot Per Minute, but reduce your in-feed rates by about 40%, this will help the crystal load and heat build up from the Carbide or PCD. They tend to make a better or easier chip to deal with, but also require quite a bit of force to cut resulting in high temperatures.

Lets talk oscillation, we recommend a cross-feed or oscillation rate of 0.010″ Per 0.50″ or P-line contact. This will help keep your hole more concentric and hold a tighter tolerance to your desired blueprints than running a straight bore or wipe/drag feed method.

Please comment or send us any questions you may have. We have been extremely lucky to be involved with the people we currently deal with. Thank you very much for reading.

Broach Grinding Wheels

By | September 16th, 2016|Categories: Diamond Grinding Wheels|

After years of exposure in the grinding industry, we found that broach grinding was a very demanded industry. Due to the size of the work piece, as well as, the complex geometry, has left only a few players in the broach grinding industry. With this demanding market with a starved supply from diversified supplies has left the broach grinding industry thirsty for a quality product that can compete. With our success in Jig and ID Grinding, we found that broach grinding wasn’t far off, we only needed some small tweaks to our formulations to handle the types of stresses that broach grinding places on a grinding wheel.

The results of us using a hardened steel or carbide shank, with specialized superabrasive crystal, mixed with our superior bonding technology has provided a “free-cutting” long tool life. These diamond plated wheels want to remove material, they hold up to fast in-feeds and hold form and finish throughout the cut. We produce anything from small diameter and small radius to large radius, large diameter wheels. Our max diameter is 1200mm or 45.27″ this is due to the limits on our CMM machine. Most broach grinding wheels are in the 4-8″ dia. with radius from 0.010 – 0.50″. Due to the small radius and our proprietary bonding methods produce a product that holds throughout the cut and minimizes the need to be dresses. When grinding slabs for a broach, large amount of material removal means that the wheel being used needs to remain open and crystal exposure needs to be optimal. Any time a wheel starts closing down and your feeding large stock removal, you can run into a loading or smug issue. This is typically cleared up by dressing the wheel to help remove that gummy material and provide crystal exposure. You can also try running the wheel at a high SFPM or spindle RPM allowing the wheel to act harder and minimize the chip load on the crystal. Sometimes your in-feed can cause some issues with loading, if you are taking too light of a cut, causing a plasma state chip to load into the structural porosity of the wheel. Keep in mind that crystal exposure and structural porosity are similar, but not quite the same. When refering to crystal exposure, remember this is exposure of a cutting edge within a chip depth cut from the outer dia. Where as structural porosity is the space and depth or peak and valley of the crystal and the bond.