Our diamond wheels are built for high-performance use and are made with ultimate precision to ensure they perform flawlessly from start to finish.
Eagle Superabrasives Diamond Wheels
Our diamond wheels are made with either poly-crystalline or mono-crystalline diamond which are synthetic, yet offer the hardness and thermal conductivity equal to or higher than that of natural diamond.
At Eagle Superabrasives, we manufacture polycrystalline diamond (PCD) grinding wheels with a vitrified bond system. By utilizing a vitrified bond, we can adjust the porosity of the wheel allowing more coolant to reach the point of grind. This keeps the wheel and the tool cool and allows for sharper edges and longer wheel life.
Our vitrified bond wheels have a tool life over 50 times longer than a generic resin bond wheel, and are easily dressed and trued on the machine.
Enhancing the cooling process of a diamond Superabrasive wheel improves the chip removal rate and reduces the amount of heat produced.
Hardness of Diamond Wheels
Diamond wheels are often graded by the hardness of the bond. The bonds high hardness allows for a longer lasting wheel when 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 or pull out from the bond easily. Contrarily, a wheel is considered hard when the grains selected do not micro-fracture and held into the bond firmly.
Typically surfaces that are easy to cut can use a harder wheel.
A softer wheel is used for a more DTG material such as sub micro-grain TCT cutting tools.
Diamond has a high thermal toughness index allowing Superabrasive wheels to cut more efficiently at elevated temperatures when compared to conventional abrasives.
The Importance of the Bond
While the diamond and coating type are an essential part of manufacturing diamond grinding wheels, the bond system selected to complement the diamond type is also a very important factor.
Our tried and true bond systems lock in the carefully selected diamond powders to ensure almost zero diamond pull out.
The careful ingredient selection process will provide a mechanical and chemical bond of the diamond particles to the bond system thus producing a long lasting, sharp and durable grinding wheel.
Diamond Wheels Applications
Diamond wheels are used to grind high hardness non-ferrous materials and CBN wheels should be used on ferrous materials with a harness above 40HRC .
Diamond wheels are great for working with difficult to grind materials (DTG) such as:
- carbide tipped cutting tools
to name only a few. Diamond wheels offer high material removal rates, fast and clean cuts without burning the surface or cracking the work piece.
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 grinding wheel compared to conventional abrasive wheels used in the industry such as aluminum oxide and silicon carbide.
While our wheels resist diamond pull out, we also incorporate porosity into our bond systems that allow coolant to be rapidly delivered to the point of grind. This limits the possibility of burning, helps to keep the wheel open and keeps the wheel cutting aggressively.
By having the diamond securely locked into the bond, you’ll be able to grind extremely hard materials with ease.
Diamond Wheel Type and Availability
We manufacture our diamond wheels as thin as 0.2mm, 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 huge variety of bonds to choose from.
Our advanced bonds ensure the integrity of our wheels, instilling a long work life. The bonds we use are selected depending on the application.
We manufacture in Phenolic Resin, Polyimide Resin, Vitrified, Hybrid, Electroplated, Vacuum brazed 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 some grinding applications:
- Diamond depending on grade and type can start to oxidize above 600F.
- Diamond reacts with ferrous metals (iron, cobalt, and nickel and its alloys) at temperatures above 700F
In light of this, diamond cannot be used to grind steel or titanium alloys, especially if the temperature exceeds 700F. This high rate of wear would make diamond uneconomical in comparison to CBN.
HYBRID BOND Diamond Wheels
Our Hybrid bond wheels are industry leaders in the manufacturing of solid carbide endmills, drills and reamers.
Eagle Superabrasives’ hybrid bonds utilize a unique bond system offering superior 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.
Hybrid bonds offer hugely reduced cycle times, with material removal rates of up to 10 times that of any resin bond product, incredible wheel edge retention of more than 20 times that of resin bond wheels, lower spindle loads, 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 20″ 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 our ability to adjust the bond structure allows for a more efficient coolant delivery to the grinding area of contact. These quality’s are key components in providing long wheel life.
Vitrified bond wheels are extremely aggressive and free cutting. They provide excellent tool life, require less downtime for dressing and truing, 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″ 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 but are typically slower cutting than resin 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 18″
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