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Diamond Grinding Wheels

/Diamond Grinding Wheels

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!)

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.

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.