Our diamond wheels are built for high-performance, with precision and provide clean cuts.
Diamond is the hardest material known to man, occurring naturally and synthetically.
Eagle Superabrasives Diamond Wheels
Our diamond wheels are composed of poly-crystalline and mono-crystalline diamonds which are synthetic, yet offer the hardness and high thermal conductivity as that of natural diamond.
At Eagle Superabrasives, we manufacture a polycrystalline diamond (PCD) with a vitrified bond system. By using a vitrified bond in diamond Superabrasive wheels, we increase the porosity allowing more coolant to easily reach the sharpening point.
Our vitrified bond wheels have a tool life over 150 times more than a generic resin bond wheel, and are still easily dressed and trued on machines.
Enhancing the cooling process of a diamond Superabrasive wheel improves the chip removal rate and reduces the contact to surface therefore reducing the heat that is produced.
Hardness of Diamond Wheels
Diamond wheels are often ranked by the hardness of the bond. It allows for a longer lasting sharpening wheel compared to conventional wheels used in the industry such as aluminum oxide and silicon carbide.
To determine the hardness of the wheel, you have to understand how the grains work.
A wheel is considered soft if the grains fracture easily. Contrarily, a wheel is considered hard when the grains selected do not micro-fracture.
Typically surfaces that are easy to cut can use a harder wheel.
A softer wheel is used for a more DTG material such as micro-grain TCT cutting tools.
Diamond is great at high temperatures, due to its high thermal conductivity tolerance, allowing Diamond Superabrasive wheels to create less friction when machining therefore expanding the overall life of the tool.
The Importance of the Diamond Bonding Layer
While diamonds are an essential part of manufacturing diamond grinding wheels, the bonding agent is a very important contributing player.
Our tried and true bonding systems lock in carefully selected diamond powders and coatings.
This ensures both a mechanical and chemical bond of the abrasive diamond material to the bond structure and the wheel core.
Diamond Wheels Applications
Diamond wheels are categorically used for plastics, synthetics and for carbides – while CBN wheels should be used on steels alone.
Diamond wheels are great for working with difficult to grind materials (DTG) such as:
- carbide cutting tools
to name only a few. Diamond wheels offer high carbide removal rates, combined with a fast and clean cut without the worry of burning the surface or cracking the workpiece.
When it comes to sharpening tools, we recommend our diamond superabrasive wheel series. Diamond, being the hardest naturally occurring element on the planet, allows for a longer lasting sharpening wheel compared to conventional wheels used in the industry such as aluminum oxide and silicon carbide.
Therefore, our wheels resist premature diamond pull out. We incorporate heightened rates of absorbency into our wheel structures so coolant can be rapidly delivered to the point of contact. By restricting the possibility of overheating, our wheels are able to resist load up during use.
Our industrial diamonds are securely bonded to our wheels, ensuring you’ll be able to grind extremely hard materials with ease. Cut through carbide cutting tips, gemstones and even concrete without breaking a sweat.
Diamond Wheels Characteristics
We manufacture our diamond wheels as thin as 0.2mm and up to a maximum diameter of 1000mm (39”) and anything in between.
We are able to produce our diamond wheels on six different core materials and have a wide variety of bonds to choose from.
Our advanced bonds ensure the integrity of our wheels, instilling a long work life. The bonds we use typically depend on the application that you are working on.
We manufacture in Phenolic Resin, Polyamide Resin, Vitrified, Hybrid, Electroplated and Metal bond systems.
Diamond Wheel Limitations
Even with a melting point of 4,000F, which is the highest of all materials, diamond still has thermal limitations in many grinding applications:
- Diamond will start to oxidize above 600F into carbon-dioxide.
- Diamond has a tendency to react with ferrous metals (iron, cobalt, and nickel and its alloys) at a temperature above 700F
In light of this, diamond cannot be used to grind steel or titanium alloys if the temperature exceeds 700F. This makes it impossible for synthetic diamond to be used for the most common grinding applications, such as the grinding of hardened steel parts. This high rate of wear would make diamond uneconomical in comparison to CBN.
HYBRID BOND Diamond Wheels
Hybrid bond wheels are the industry leader in the manufacturing of solid carbide endmills, drills and reamers.
Eagle Superabrasives’ hybrid bonds utilize a unique bond system offering superior tool edge retention and stock removal rates that were unheard of a few years ago. Our bond system is comprised of a mixture of specially selected alloys, ceramics, diamond powders and coatings, all sintered in environmentally-controlled furnaces.
They offer the benefits of hugely reduced cycle times, with material removal rates of up to 10 times that of any resin bond product, wheel edge retention of more than 20 times that of resin bond wheels, lower spindle load, excellent thermal stability, reduced tool deflection, longer spindle life and no thermal damage to the tool.
We are currently able to manufacture hybrid bond wheels up to 10″ diameters.
RESIN BOND Diamond Wheels
Resin bonds are the most commonly used bond system for superabrasive grinding wheels. They are used for grinding all types of tungsten carbide tools, ceramics, glass, ferrites, refractories and semi-conductors. It offers good elasticity, superior surface finish and highly efficient grinding performance, all at an affordable price.
Resin bond wheels come in two varieties: Phenolic and Polyimide.
- Phenolic resins are typically used for wet or dry grinding, off-hand grinding, centerless grinding and general purpose tool room use.
- Polyimide resins offer a considerable performance increase over generic phenolic resins. You can expect to see greater stock removal, better form holding, higher temperature tolerance and minimal wear when grinding with polyimide bond wheels.
At Eagle, we manufacture resin bond wheels up to 30″ in diameter every day.
Vitrified Bonds for Diamond Grinding Wheels
Vitrified bond wheels are typically used for grinding PCD and PCBN tools, ceramics and semi-conductors.
The combination of the vitrified bonds high thermal stability and its ability to maintain wheel structure allows for a more efficient coolant delivery to the grinding area of contact. This quality is a key component in providing longer wheel life.
These wheels are extremely aggressive and free cutting. They provide excellent tool life, require less stoppages for dressing than their resin bond counterparts, are cool-cutting and are suitable for “lights out” high production grinding.
Eagle vitrified bonds range from 3/16″ diameter all the way to a 40″ segemented diameter.
METAL BOND Diamond Wheels
Typical applications for metal bonds are grinding glass, ceramics, refractories, ferrites, tile, stone and quartz.
Metal bond wheels offer the best grit retention and a very long service life. They are industry-leading for form holding, but require high horsepower machinery and are significantly slower cutting than resin bonds and other bond systems. Metal bonds work best when grinding a very abrasive material.
Eagle metal bond wheels start at a minimum diameter of 3/8″, and max out at 16″.
Trust the Experts
When you’re ready to try the best, trust the experts at Eagle Superabrasives. We offer an unparalleled customer support and service.
With an extensive inventory of over 6,000 diamond, CBN and CDX wheels in stock at our Hickory, North Carolina location, we are capable of shipping 90% of orders same day. Custom orders can be shipped in as little as seven days.
Our experienced staff is dedicated to providing our customers with high quality products and unequaled service. We offer experienced technical support and advice to assist you along the way.
We look forward to meeting all of your grinding wheel needs.
To learn more about Diamond Grinding Wheels, click the articles below:
- Diamond Concentration on a PCD Diamond Wheel
- Diamond Wheel Cost versus Diamond Wheel Life
- Diamond Wheel That Keeps Its Shape
- Diamond Wheel – Troubleshooting
- Diamond and CBN Wheel Shapes
- Diamond vs CBN Wheels
- Diamond and CBN Wheel Speed
- Diamond or CBN particles per carat
- Which Diamond Wheel Last the Longest
- Fluting Speed versus Diamond Wheel Life