High Performance Grinding Solutions
High PerformanceGrinding SolutionsSAK ABRASIVES LIMITED
SAK ABRASIVES LIMITEDSak Abrasives Limited started in 1997 with the objective of supplying Indian Industries withhigh-performance grinding wheels at affordable prices. At that time the growing Indian marketwas supplied by very few companies and the trend towards precision-engineered productsleft a void that we were quick to fill. In collaboration with the Swiss company,Rastawerk – Switzerland A.G, we started our range with basic resin bonded DC andcut off wheels made out of a plant in Chennai, India.Since then there has been no looking back as we expanded our product line in response tothe evolving need of our customers. Backed by a philosophy of rapid but sustainable changewe developed a full range of resin and vitrified bonded abrasives, coated abrasives and thelatest addition of Super Abrasives. This has been accompanied by continual investment in theup-gradation and modernization of our plant, paving the road to the future.TOPLINEIrrespective of whether you are regrinding or making new tools, we have the diamond orCBN grinding wheel for you. With the help of our technical partner, Superabrasives INC, USA,we have worked with a number of OEM's and we understand the machinery demands and therequirement of grinding wheels. Products like Carbide, Stainless or High-speed steel end mills,drills, punches, reamers and hole saws require multiple steps in manufacturing and we havedeveloped bond systems and have qualified exact specifications for each operation. With thelatest technology, we are offering all types of Diamond / CBN wheels that comply withFEPA standards and that are used on CNC machines such as Walters, Rollomatic, ANCA,Royces, Wendt, TGT, WIDMA etc. in the following industries / applications:- Rotary Tools- Cutting Tool Industries- Wood Working Tools- Tool Resharpening / Restoring- Optical Profile GrindingLet the sparks fly.
Usage of Diamond and CBN wheelsIn general, Diamond is used to grind Non- ferrous material as it reactswith iron. On the other hand, CBN is used to grind Ferrous material.CBN (CB)DIAMOND (D)Solid CarbideOxide CeramicsGlassStoneProcelain, Stone WareSemi-conductorsFerriteStellite- hard facingCast IronHigh Speed SteelTool SteelHeat Treated SteelChromium SteelCase Hardened SteelSuper AlloysBearing SteelStainless SteelInconelGRIT SIZEWHEEL SHAPEAPPLICATIONSFlutingPrimary and secondary relief or end workGashingGrinding top/bottom insertsGrinding peripheral insertsOD grindingCenterless grindingSurface grinding1A1,1V1,1F111V91V1, 12V9 – 30 or 45 6A22A2T1A1, 1A1J1A1, 1A1J1A1Shape Of Wheels14F114A1DDXUTHJHJ2R RSERXDUFEPAX3A1USAHJHJSAK Wheel NomenclatureD64 B4 602SWD: Abrasive Type64: Grit SizeD: DiamondCB: CBN(FEPA StandardD64-230/270,D76-200/230 etc)64: Finishing126: RoughingSak Abrasives Limited2: ConcentrationS: Sak Abrasives(25-1 ,50-2 , 75-3,100-4 . Etc)W: Wet GrindingD: Dry GrindingB: Resinoid602: Bond Type601: Carbide, coolant with Oil, Face602: Carbide, coolant with Oil & Water, Profiles603: Steel, coolant with Oil & Water, profile & slicing604: Steel, coolant with Oil & Water, ID, Face & Dry Grinding.605: Carbide & Steel, coolant with Oil & Water, OD, ID,Plunge, Surface, Centre less for Grit 325 and above606: Carbide, coolant with water, OD, Plunge, Surface, Centre LessTH’D.
PRODUCT IDENTIFICATIONANSI Wheel Shape Identification System11 B 91 Choose basic core shape3 Select location of abrasive section2 Choose shape of abrasive cross section1. Choose basic core shape123469111214152. Abrasive Cross Sections And MarksAAHFBFFCGMDCHJHDDKPQQQUVYELEELLS3. Location of abrasive section & marks3. Both Sides6. Part of periphery9. Corner4. Inside Bevelor Arc1. Periphery7. Part of side10. Annular2. SideNote: Solid black area indicates abrasive placement.5. Outside Bevelor Arc8. ThroughoutSak Abrasives Limited
TECHNICAL INFORMATIONTechnical GuidelinesAvoid Grinding SteelAvoid steel when grinding withdiamond wheels. Keep theamount of steel ground to anabsolute minimum.On brazed tools, use aluminumoxide wheel to back off the steelshank.A high lubricity grinding fluidshould be used.Use Rigid Work SupportCoolant – Grind WetAll workpieces should besupported firmly during thegrinding process. Any amount ofvibration will cause wheel wearand produce chatter or wavemarks on the ground surface.On work ground betweencenters, centerholds should beproperly prepared.Minimize work overhang.If the ground work is supportedby a work finger, ensure thefinger is strong enough toprovide vibration-free support.Diamond wheels should beused with a full flood coolantproperly directed towards thegrinding zone. Water with a rustinhibitor is recommended.When flood application can’t beused, try mist or spray application.Use compressed air to“atomize” water or soluble oil.Avoid Excessive FeedsExcessive feeds will result inpremature wheel wear.Excessive feed rates arecharacterized by:- A hard grinding sound- Chatter- Burn- High wheel wear rate- VibrationDirect the spray at thegrinding zone to helpdissipate heat and preventheat damage to the work.Spec CheckTROUBLESHOOTING GUIDE – DRY GRINDINGPOSSIBLE CAUSESPROBLEMSUGGESTED CORRECTIONBurning (excessive heat)Wheel loaded or glazedExcessive feed rateWheel too durableDress wheel with a dressing stickReduce infeed of wheel or workpieceUse freer cutting specification or slow down wheel speedPoor finishGrit size too coarseExcessive feed rateWheel out of truthSelect a finer grit sizeReduce infeed of wheel or workpieceTrue wheel; ensure it is not slipping on mountChatterTROUBLESHOOTING GUIDE – WET GRINDINGPOSSIBLE CAUSESPROBLEMSUGGESTED CORRECTIONBurning (excessive heat)Wheel glazed or loadedPoor coolant placementExcessive material removal rateRe-dress wheelApply coolant directly to wheel/workpiece interfaceReduce downfeed and/or crossfeedPoor finishExcessive dressingChatterGrit size too coarsePoor coolant flow or locationWheel out of truthUse lighter dressing pressureStop dressing as soon as wheel starts to consume stick rapidlySelect a finer grit sizeApply heavy flood so it reaches wheel/work interfaceTrue wheel; ensure it is not slipping on mountWheel will not cutGlazed by truingWheel loadedSlow cuttingLow feeds and speedsShort wheel lifeIncorrect coolant flowLow wheel speedExcessive dressingWheel too soft or too hardDress lightly until wheel opens upDress lightly until wheel opens upIncrease coolant flow to keep wheel surface cleanNever run wheel with coolant turned offIncrease feed rate; increase wheel speed(Do not exceed wheel MOS)Apply coolant to flood wheel/work surfaceIncrease wheel speed (observe maximum operating speed)Use lighter dressing pressureChange grit or grade; use higher concentration70006000Superabrasives is a term used to describe thoseabrasives of extreme hardness, which produceoutstanding results when properly used onspecific applications. The following chart provides ahardness comparison (Knoop Hardness Scale)between diamond and CBN superabrasives,aluminum oxide and silicon carbide standardabrasives, and some common materials theseabrasives are used to grind.Knoop Hardness (H.K.)MATERIAL HARDNESS ndondrasiNitrCarbCarbCarbAbraiam BN Abre AbDiamoronstenxideCliconne Ddium lumPolyPolyrceel Hd StHarsGlasteelSSoftHrb85
RECOMMENDATIONS & GUIDELINES FOR THE SELECTION OF CONCENTRATION INRELATION TO GRINDING FORCESGRINDINGFACTORSAREA OF CONTACT BETWEENWHEEL & WORKPIECEPROFILE &CUTTING EFFICIENCYEDGE STRENGTHSOFT trationHighLowSurface FinishThree factors affect the choice of Abrasive grit:Quantity of material to be removedSurface-finish and wheel lifeMaterial removal and wheel lifeSurface Finish depends on the adjustment for oscillation-grinding (on pass and in-feed depth) and forplunge-grinding. A wheel used properly shows a grit penetration depth equal to 1/5-1/8 of the grit dimension.If the level of roughness needed is known, it is possible to choose the right grit using the following charts:Permissible Cutting DepthFor Oscillation Grindingmm0.040.035Cutting 4D64D76D91DDD107 126 151D181FEPA grit sizeD213The Concentration specifies the carats of theabrasive grain (Diamond or CBN) processed inthe 1cm3 abrasive layer.The Concentration influences the performance of theDiamond and CBN Grinding tools decisively.It effects:The service life of the grinding toolThe stock removal rateProfile retentionThe dimensional constant of the machined work piece.The finish smoothness of the machined work piece.The price of the grinding toolSurface Finish Vs Grit SizeSelection Guideline for Grinding of Carbide & Ceramics1811077654157(cutting speed approx.: 25m/sec - table speed 15m/min - coolant 40,416N50,832N61,664N73,2125N8Sak Abrasives Limited
Expected Surface Finish by Grit SizeUse these charts as guides only. Surface finish is affected by several variables: machinetype and condition, type of material ground, coolant, wheel speed, bond system, etc.DIAMONDMAXIMUM DEPTH OF CUTPER PASS FOR GRIT SIZEINCHMMGRIT SIZEEXPECTED FINISHMICRO INCH AAEXPECTED FINISHMICRON Ra10012015018022032040024 - 3216 - 1814 - 1612 - 1410 - 1287-80.60 - 0.800.40 - 0.450.35 - 0.400.30 - 0.350.25 - 0.350.20 - 0.250.18 - 0.20GRIT SIZEEXPECTED FINISHWITH OSCILLATIONEXPECTED FINISHMICRON RaEXPECTED FINISHPLUNGE10012015018022032040035 - 4030 - 3525 - 3020 - 2515 - 2010 - 154-80.875 - 1.0000.750 - 0.8750.625 - 0.7500.500 - 0.6250.375 - 0.5000.250 - 0.3750.100 - 0.20040 - 4535 - 4030 - 3525 - 3020 - 2515 - 205 - 100.001” - 0.002”0.001” - 0.002”0.001” - 0.002”0.0007” - 0.001”0.0007” - 0.001”0.0004” - 0.0006”0.0003” - 0.0005”0.025 - 0.0510.025 - 0.0510.025 - 0.0510.018 - 0.0250.018 - 0.0250.010 - 0.0150.008 - 0.013CBNRecommended Wheel Speeds for Diamond and CBN WheelsWET GRINDINGCUP WHEELSDiamond Grinding WheelsResin Bond WheelsCBN GRINDING WHEELSResin Bond WheelsPERIPHERAL WHEELS11V9, 12V9, 15V9, etc.4921 to 7874 SFPM25 to 40 m/s1A1, 1V1, 1A1R, etc.4921 to 7874 SFPM25 to 40 m/s5906 to 9843 SFPM30 to 50 m/s5906 to 9843 SFPM30 to 50 m/sDRY GRINDINGCUP WHEELSDiamond Grinding WheelsResin Bond WheelsCBN GRINDING WHEELSResin Bond WheelsPERIPHERAL WHEELS11V9, 12V9, 15V9, etc.2756 to 3543 SFPM14 to 18 m/s1A1, 1V1, 1A1R, etc.2756 to 3543 SFPM14 to 18 m/s2953 to 5906 SFPM15 to 30 m/s2953 to 5906 SFPM15 to 30 m/sWHEEL SPEED CALCULATION:To convert m/s to SFPMTo convert SFPM to M/STo convert RPM to SFPMMultiply M/S x 196.85 SFPMDivide SFPM by 196.85 M/SMultiply wheel diameter in inches x RPM x 0.262M/S Meters/secondRPM Revolutions Per MinuteSFPM Surface Feet Per MinuteSak Abrasives Limited
w w w . s a k a b r a s i v e s . c o mMarketing OfficeFactoryEmail USSP Infocity, 40, MGR Salai,Perungudi, Kandanchavadi,Chennai - 600 096B-49/W, Sipcot Industrial Complex,Gummidipoondi - 601 201INDIAsuper@sakabrasives.comPhone: 91-44-2792 3104Fax: 91-44-2792 3009INTERNATIONALexports@sakabrasives.comWeb: www.sakabrasives.comPhone: 91-44-2454 3500Fax: 91-44-2454 3510
0.25 - 0.35 0.20 - 0.25 0.18 - 0.20 DRY GRINDING WHEEL SPEED CALCULATION: CUP WHEELS CUP WHEELS PERIPHERAL WHEELS PERIPHERAL WHEELS Diamond Grinding Wheels Diamond Grinding Wheels To convert m/s to SFPM To convert SFPM to M/S To convert RPM to SFPM Resin Bond Whee
29. Grinding Machines Grinding Machines are also regarded as machine tools. A distinguishing feature of grinding machines is the rotating abrasive tool. Grinding machine is employed to obtain high accuracy along with very high class of surface finish on the workpiece. However, advent of new generation of grinding wheels and grinding machines,
different operations like turning, threading, tapper grinding, end drilling etc. The plant has the capacity to do most of operation except taper grinding. Presently the plant has to outsource the shaft to outside plant for the taper grinding. presently the plant have a grinding machine of G 17-22U, which means it is a universal grinding machine that can machine a job up to 220mm diameter shaft .
Grinding wheel selection, Qw, Vw Wheel dressing parameters Limitations of on-board inspection Grinding Wheel 101 Grinding wheel definitions and descriptions Dressable and Non-dressable grinding wheels Tool wear Hands on Lab or Gear Grinding Simul
difficult to grind than conventional structural steel. In order to achieve successful results when grinding tool steel, it is necessary to choose the grinding wheel with care. In turn, choosing the right grinding wheel and grinding data requires an understanding of how a grinding wheel works
A grinding wheel's surface texture has a strong influence upon its grinding performance. This is clearly evidenced by the increase in grinding forces, power consumption, and cutting zone temperatures as a wheel wears [Butler and Blunt, 2002]. If the surface texture of a grinding wheel could be measured and quantified, then it could be
32 Storage of Grinding Wheels 32 DressiNG WiTH DiamOND DressiNG 33TOOLs Basic Guidelines 33 . Twin Wheel Surface Grinding 66 beNcH, fLOOrsTaND, sWiNG frame macHiNe 67 . and also of CNC tool grinding machines for grinding
grinding marks by means of a Magic Mirror. The grinder records the grinding force automatically. The grinding force measured is the interaction force between the grinding wheel and the wafer in the direc-tion parallel to the spindle axis. It is also the direct
-Surface speeds involving grinding are very fast. 3 types of action Cutting, rubbing and plowing actions occur (a) (b) Grinding Process. Grinding Forces A knowledge of grinding forces is essential for: -Estimating power requirements. -Designing grinding machines and work-holding fixtures and devices. -Determining the deflections .
