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Jig Grinding

/Jig Grinding

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.

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.