Diamond grinding wheels contain commercial-grade synthetic diamonds, as well as carbides and ceramics. Natural diamonds are a type of carbon that is extremely valuable. However, they are sometimes used to grind extremely hard materials such as cement, cement carbides, marble, granite, and stone. Natural diamonds are also used in diamond-tipped drill bits and saw blades that are used to cut or shape rock, concrete, grinding wheels, glass, quartz, and other gems, as well as high-speed tool steels. Diamond abrasives offer the precision required to finish harder surfaces. Ceramics, for example, are difficult to shape and finish unless precision grinding wheels are used.
Diamond grinding machines are widely used by manufacturers because they can be used to effectively shape and finish metals and other materials that are used to make parts for a variety of industries. They are used to manufacture bearings, camshafts, and rotors for jet engines in the automotive sector. Ceramic and metallic medical and dental products are made using diamond and CBN grinding wheels. This is possible by using controlled grinding and preserving the smoothness of these grinding wheels. These wheels are used to create surgical instruments, dental implants, and prosthetics. Diamond grinding wheels are used to provide the finish on ceramic automotive parts because they are a good way to finish asymmetrical shapes and surfaces. They are also used to grind aerospace and flight control components that require extreme precision. Custom-made diamond grinding wheels are used to create super ceramic pump seals for Space Shuttles.
Because diamond grinding wheels can be costly, all users must understand how to extend the life of their grinding wheels. Several things can be done to easily extend the life of the wheels while also contributing to a high material removal rate. Wheel speed, feed rate, work speed, and coolant use are all factors that contribute to the wheels' longevity and efficiency.
The performance of a diamond grinding surface is determined by the speed of the wheel. Grinding speeds of 4000 to 6000 sf/ruin (20 to 30 m/s) are ideal for wet surfaces. If the speed drops below 4000 sf/min, the efficiency drops and speeds above 6000 sf/min reduce wheel life. The speed should be medium for dry tool and cutter grinding with grit sizes of 150 and concentrations of 75 to 100. Dry grinding performs best at speeds ranging from 3500 to 4500 sf/min (18 to 23 m/s). Grinding at speeds greater than 4500 SF/min (23 rn/s) can damage the diamond grinding wheel, especially if coolant is not available. If coolant does not damage the workpiece material, it must be used when dry grinding at high speeds. Work speeds must also be such that they do not cause excessive wear and tear or damage to the wheel or the work.
Another area of application is the feed rate or the depth of the cut. Diamond grinding wheels can become chipped, burned, or cracked over time. In this case, the wheel will be unable to achieve the desired size, finish, or form in the workpiece. When face grinding cemented carbides, taking a heavy cut too quickly can be especially dangerous because the carbide can damage the wheel face. Heavy cuts on the periphery can cause the wheel to climb the material and come out to the other side, causing the wheel to be damaged. Allow the grit size to determine the depth of the cut. If the feed rates are not kept to the manufacturer's specifications, the work material can cut the diamond grids. To produce less heat during dry grinding for tools and cutting, use a resin-bonded diamond grinding wheel.
These effectively provide the required productivity while requiring no coolant. On dry grinds, it is preferable to maintain the speeds and feed rate rather than use coolant, as the alternate heat and cold treatment can also damage the grinding wheel. A steady stream of coolant is preferable to on-and-off use when wet grinding.