Mounting: Truing Dressing: Has@®o THTERWATIONAL CARBIDE General Information for Use of Diamond and CBN Wheels Flanges, plates, and spindles should be clean, free of burrs and run true. ‘Maximum run-out should not exceed .005" for straight type wheels or 001" for cup wheels. ‘After mounting, Diamond and CBN wheels should be trued with brake truing device. After truing, the wheel will be glazed and must be dressed aggressively to ‘expose the crystals. To dress the wheel, select a dressing. Properly Dressed Wheel Face Gece as oe en el 1) To dress the wheel, select a dressing stick one or two grit sizes finer than the abrasive in the diamond or CBN wheel, 2) Turn off the coolant pump, 3) Turn on machine and allow the grinding wheel to reach full pm, then, turn off the spindle motor. 4) Apply the dressing stick to the abrasive section on the whee! with medium to light pressure until the wheel stops rotating 5) Repeat step 4 until the dressing stick feels lke it is being pulled or drawn into the wheel. This may need to be repeated up to four or five times depending on the condition of the wheel surface. 6) The whee! is now ready for use with the abrasive crystals exposed and ready {or efficient grinding 7) We do not include dressing sticks with our wheels as the mold skin has and the wheel is supplied ready for use. When the Is used correctly and is in the self sharpening mode, it will run for the rest of its life without the need to re-dress. I the wheel is not used in this zone then periodic dressing will be required. To alleviate this problem and get the wheel into the self sharpening mod increase the infeed by 10% until the loading ceases. Eagle International Carbide » PO Box 5639 « Statesville, NC 28687 Tel: (800) 633-8068 or (704) 878-9583 « Fax: (800) 683-8810 or (704) 878-9585 sales@eagle-carbide.com * www.eagle-carbide-comWarning: Coolant: Wheel D0 NOT USE CLUSTER OR SINGLE POINT DIAMOND DRESSING TOOLS FOR TRUING DIAMOND OR CBN WHEELS. Although resin bond wheels may be used dry, the use of coolant will increase efficiency and greatly extend wheel lf. Flood coolant is recommended where possible. Always ensure that coolant is directed at point of contact between wheels and work piece. Keep filtration systems clean. A speed range of between 5000 and 7000 SFPM (surface feet per minute) is recommended for EagleCut wheels. The lower speed range makes the wheel act softer and coarser, while the higher speed range makes the wheel act harder and finer. RECOMMENDED RPMS: Formula: WHEEL DIAMETER RPM RANGE Ey ‘5200 ~ 8000 " 4600 - 6500 s 3600 - 5000 e 3200 - 4200 ts 2600 ~ 3600 s 2300 - 3000 10" 1800 - 2500 To calculate wheel speed in SEPM — Dia. (in ft.) x 3.142 x RPM Thank you for purchasing your world class Superabrasives from ad®o TUTERMATIONAL CARBIDE We appricate your business! Eagle International Carbide # PO Box 5639 « Statesville, NC 28687 ‘Tel: (800) 633-8068 or (704) 878-9583 © Fax: (800) 683-8810 or (704) 878-9585 sales@eagle-carbide.com * www.eagle-carbide.comDiamond and CBN Superabrasive wheels. ‘The basics. How they are made. ‘The Diamond or CBN abrasive section is made by using the following materials. Diamond or CBN powder Plastic resins Filler materials. Core material, typically some grade of Aluminum alloy, Powdered Aluminum and resin mix, steel, copper or composite cores There are two ways to produce diamond sections. 1) First is to press the diamond or CBN section as a ring and then glue it to the wheel core in a separate process, this is older technology and while still suitable for some applications most of the wheels produced by us use the 2nd method. 2) This method is by far the best, it allows a perfect bond between the diamond section and the wheel core. The section is pressed as follows, we start with an outer ring that is the same size as the diamond OD, a pressing ring that is the same width as the diamond section and the third piece is made up of some part of the wheel core which is normally the ID of the abrasive section. Which ever method of pressing is used, the powders are mixed together and spread into the cavity of the mold and time is taken to make sure the power is spread evenly. Then the pressing ring is carefully put in place. The whole assembly is then taken to the hot press that usually consists of a double heated plattern and pressed to a pressure of between 10 — 100 tonnes, at temperatures ranging from 350f to 900f depending on the resin type and bond structure, After hot pressing, the wheel or diamond or CBN ring is allowed to cool and then removed from the mold, it is then placed in the post curing oven for up to 3 days depending on the bond type. After this, final machining, grinding, truing, balancing, polishing and engraving is done. Bond types. We break down bond types in to the following categories. 1) Metal Bond - comprised of powdered brass, bronze, copper, based matrix that is pressed and sintered — Benefits, highest grit retention. Longest life, best form holding Negatives, High power needed to drive wheel. Slow cutting, Typical uses, Stone, glass, quartz cutting, Concrete cutting2) Vitrified bonds, often referred to as Vit bond or glass bonds, made from vitrious ‘material. Sintered at high temperature, Benefits, Very aggressive cutting, low heat generating, easy to condition or true. Negatives, Very expensive, must be used correctly or you will have an expensive pile of junk. Typically need sophisticated machinery with automatic dressing and conditioning functions to obtain best results. Typical uses, Cam shaft, crank shaft, bearing, PCD and PCBN can all be ground very efficiently with vit bonds. 3). Resin Bonds, two basic types of resin are used. Phenol or Phenolic resins, these are lower tech and lower temperature resins, but are still most suitable for low hp spindles, dry grinding operations, off hand grinding and general purpose tool room use Polyimide resins, these are high performance, high heat tolerating resins that are useful for high stock removal applications such as round tool or endmill manufacturing, These resins require high HP, and high coolant pressures to be beneficial Benefits, Rapid stock removal, low heat generating, easy to true and dress, durable and relatively inexpensive. ‘Negatives, can wear rapidly when not used at the correct rpm. 4) Electro-plated bond. A single layer of diamond of CBN attached to a steel core through Nickel plating. Benefits. Very rapid stock removal, cool cutting. Can be re-plated on same core after abrasive layer wears out. Great form holding ‘Negatives, Just a single layer of abrasive material, Nickel coating. Filler types. Different filler materials, such as Silicon carbide powder, Aluminum oxide powder, copper powder are used as filler materials and act as links between the resin and superabrasive material. Dry lubricants are also added such as graphite and PTFE to aid in dry grinding operations. If a wheel has a silicon carbide based filler, then the wheel will normally take on a green color, copper fillers will typically show as brown or copper color. Each filler has its own benefits and negatives that are perhaps to detailed for this discussion,Superabrasive materials. These are broken down into two basic types, but again with a million variations of the theme, CBN or Cubic Boron Nitride — This material is used for grinding Hardened steels above 42 hrC — M2, D2, Tool Steels, ‘Two basic types of CBN are used. Black CBN and Amber CBN Black CBN tends to be more friable and has found good use in grinding, ‘machining and turning exotic alloys Amber CBN in typically used for Ferrous based tool steels Diamond - used to grind TCT tipped cutting tools, Diamond crystals are separated into two basic categories, Friable and Blocky. This describes the crystals capability to micro fracture. The blocky crystals are typically used in Metal bond applications, these do not micro-fracture and will dull or round over the comers and almost drag through the work piece, but they are able to tolerate the high temperature needed to sinter metal bond wheels. Friable diamond and normally used in resin and Vitrified bond systems, they have the tendancy to micro-fracture during use ( typically as the cutting force increases past a given point ) and when the microfracture occurs, it will produce a new, sharp cutting edge, Micro- fracturing can occure up to 50 times per erystal before expulsion from the bond. Coatings, Superabrasive materials such as Diamond and CBN are often coated with Nickel, Copper, Ceramic, Titanium type coatings. ‘These coatings help to retain the diamond or CBN particle in the bond for longer tool life. Copper coatings can be used in dry grind applications as it helps to pull away heat from the point of cut. Nickel is typically used for wet grinding. Titanium coatingf help protect the didiamond from oxidization during high sintering temperatures. Ceramic can be used for difficult to grind materials such as Semi-conductors etc. Coating thickness can vary by weight, some are 15% - 30 % of crystal weight, and can go as high as 60% of crystal weight. The heavier the coating the better the crystal retention. ‘Wheel hardness or durablity Wheel hardness can be varied in many, many ways, but typically for a given bond system, the hardness is varied by the percentage of coated diamond and also the weight of the coating. The other common way is to increase the amount of superabraive material. For example to go from 75 Con ( 3.3 cts per cubic cm ) to 100 con ( 4.4 cts per cubic cm ) or to 125 con (5.5 ets per cubic em )Increasing con to improve wheel life sounds like a good idea until you get to the point where you have so many cutting edges exposed that the wheel generates so much heat it degrades the bond system which in tun allows the diamond particles to fall from the bond with out being used properly and life goes down the toilet.