Diamond Wheel Troubleshooting

The fine grit diamond wheel is cutting better than a coarse grit wheel?

  • Is the wheel loaded or glazed up?
    • If so, it needs to be dressed according to our recommendations
  • Was the wheel was directly removed from the box and did not cut?
    • Stick the wheel open prior to installing it on the machine
  • Are the RPM’s within the correct range for the bond type?
  • Are the wheels made in the same bond?

My diamond wheel is not lasting as long as it used to?

  • Is the wheel being used for the same application?
  • Does the wheel sound the same?
  • The drive belts between the motor and spindle could be slipping.
  • Tool clamping could be loose or to far from point of grind causing vibration.
    • Is the clamp close enough to the periphery of the blade when saw grinding?
  • Is the wheel spinning or slipping on the arbor?
  • Are the wheel RPMs dropping during  grinding?
  • Is it a different carbide grade than usual?
  • Excessive spindle wear or bad spindle bearing
  • Is the wheel bond / specification the same?

The diamond wheel is louder than it used to be?

  • Is the wheel loaded or glazed over?
  • Is clamping loose causing vibration and chattering in the wheel?
  • Are the spindle bearings bad?
  • Did the spindle speed change?
  • Is it a different carbide grade?

How to fix run out on diamond wheels?

  • Remove flanges from the wheel and clean  thoroughly. Put the flanges back on and check again for run out.
  • Check the bore hole for scoring, scratches, or other defects
  • Check the machine spindle for run out
  • Check the spindle bearings with a dial indicator
  • Dress the wheel to the arbor

The diamond wheel is getting too hot (bluing on the part)

  • Adjust the spindle speed
    • Spindle speed maybe too high
  • Incorrect coolant nozzle placement
  • Using the wrong type of coolant
  • If the wheel is glazing up try taking heavier passes to keep it open
  • Try take lighter passes if wheel is loading up due to Micro-grain carbides
  • Lower the Diamond/CBN concentration
  • Use a coarser grit if possible
  • Are you grinding a micrograin carbide, if so, slow feed rate?

Your diamond wheel is acting softer than the previous supplier’s wheel

  • Is the finish the same as you were getting from previous supplier
    • Grit could be finer or coarser based on supplier
    • Are the wheel spec’s the same as the previous supplier
  • Is the bond color the same as old supplier
  • Check the machines belts for slippage
  • Is the spindle speed correct ?
  • Has the diamond wheel grinding surface been properly opened up?

The diamond wheel is acting softer than it used to

  • Check the grinding machine spindle bearings for any play
  • Check for grinding machine belt slippage between motor and spindle
  • Are the RPMs decreasing during grinding?
  • Did the bond or wheel spec change?

Dressing sticks are not dressing the wheel

  • The dressing stick should always be one to two steps finer than the superabrasive wheel grit
  • If it is a very fine wheel (D600 or finer) we don’t have a dressing stick that is able to dress it because it will rip out the diamond

Why can’t I use the same wheel if a switch from water to oil based coolant?

  • Water based coolant absorbs heat from the grinding process much better than oil based coolant
  • Oil coolants typically needs a softer sharper bonded wheel
  • Oil acts as lubricant between the wheel and tool where as water coolant does not.
  • Changing to oil from water based coolant can cause tips to blue and the wheel not to cut as well

EC wheel causing more burrs

  • Voltage/Amperage settings are too low
  • Make sure you are using a CBN wheel for best results
  • Adjust spindle speed up and down to get best finish
  • Slow down the cutting process
  • Dress or open the grinding section of the wheel to expose new sharp cutting edges

Can I dress a metal bond wheel?

  • Wheel should be self-dressing if used at the correct feeds and speeds for the material type
  • Typically metal bond wheels need to be reconditioned with spark erosion process to expose new abrasive
  • Ask us about companies that will dress your wheel for you.
  • We will only re-dress metal bond wheels that are made by us.

Hitting a gullet when facing is causing the diamond section to come off

  • Set the stops accurately in order to stop the wheel hitting the gullet
  • Use a smaller abrasive section such as 1/8” section instead of a 1/4”
  • You may notice a burr around the edge of the diamond wheel core due to the wheel hitting the gullet, this can cause diamond to separate from the wheel body

Causes of a poor surface finish and how to resolve

  • Vibration in the wheel or spindle
    • Clean flanges and spindle, reinstall and check for run out on wheel face.
    • Open the wheel structure with dressing stick
    • Change the spindle bearings if any play is detected
  • Check the belts and spindle
  • Wheel should be mounted on adapter and trued
  • Coolant placement could be off
  • Coolant filtration
  • Wheel is too soft and aggressive
  • Wheel is too hard causing bouncing or vibration
  • RPMs can vary the finish
  • Excessive Dressing
    • Use less pressure on the dressing stick
  • Reduce down feed or cross feed