Continental Diamond Tool Limited Soars with Record Sales Driven by £1.6 Million Investment

(From left to right) Michaela Lawton, Jeff Wirth, Troy Giacherio, and Justin Hughes in Continental Diamond Tool Limited’s new plating lab.

Continental Diamond Tool Limited — CDT’s subsidiary stationed in Kinmel Bay, Conwy, in North Wales— is experiencing an era of remarkable growth thanks to a substantial £1.6 million investment initiative. According to Jeff Wirth, the Managing Director, this rapid expansion is a result of a perfect blend of Welsh dedication and backing from its American stakeholders.

"As part of our expansion strategy, we opened a second production unit, which has facilitated the establishment of a new electro-plating operation. With support from the Welsh Government, this move marks a significant leap for us," said Wirth.

Continental Diamond Tool Limited is a niche outfit, one of merely two similar enterprises in the UK that specializes in crafting diamond-encrusted rotary dressers and grinders. The team designs their custom products for diverse manufacturing sectors like aerospace, automotive, medical, and semiconductor industries.

"In aerospace, our rotary diamond dressers play a pivotal role in crafting engine parts for prominent aircraft like the Boeing 777 and 787 Dreamliner, as well as the Airbus A330-A380 series," commented Wirth. These aircraft parts are notably crafted at the Airbus facility in Broughton.

"Over 60% of our products find their way to 30 countries globally, experiencing substantial growth across Europe, Asia, and North America," added Wirth.

Originally founded as Consort Precision Diamond, the company will be celebrating its 40th anniversary in April of next year (2024). In 2018, it underwent a timely transition when Continental Diamond Tool Corporation acquired it. During the COVID-19 pandemic, the company showed resilience amid adversity as it pivoted its product range to mitigate a significant loss of orders in one of its largest sectors due to grounded passenger planes.

"It would have sunk most companies, but we had already started our diversification and a pretty significant culture change here," remarked Wirth during a visit from the States. "Sales are now at a record high. Over the last five years, our Rotary Diamond Dresser product line in Kinmel Bay has seen remarkable growth of over 70%, despite the negative effects of COVID," he continued.

CEO Nick Viggiano noted, "We believe in the workforce here, we believe in the people, their work ethic, their can do spirit, and the pride they take in their work. At CDT headquarters in New Haven, Indiana, the culture is the same. When you take modern technologies and join it with that culture, it’s a recipe for success.”

"The new energy and substantial investment brought by the new owners has been a game-changer," echoed Michaela Lawton, the finance manager. "We've also had a good relationship with the Welsh Government for some time. The latest support with the £90,000 we received from the Smart Cymru fund helped fast-track the new technology that we introduced through the electro-plated product."

The project has been a source of great pride to production manager Justin Hughes who’s been working at the Kinmel Bay site for the past 17 years.

He said:  “We’ve got the backing of the American parent company behind us which enables us to push forward with investment in machinery and people to aim at new markets. It gives us reassurance and confidence as we continue to grow and develop.”  

"The company is on an upward trajectory in terms of growth, turnover, profit, and being able to further diversify our product range is the next step forward,” adds Lawton. “It's a very exciting place to work, and the sky really is the limit.” 

Related News Links:

https://www.rhyljournal.co.uk/news/23936389.kinmel-bay-engineering-firms-sales-jet-propelled-1-6m-investment/

https://www.business-live.co.uk/manufacturing/global-engineering-firm-north-wales-28144996

https://www.herald.wales/north-wales/global-engineering-firms-record-sales-are-jet-propelled-by-1-6m-investment/

http://www.baysideradio.co.uk/news/kimmel-bay-global-engineering-firm-propelled-by-1-6m-boost-8260

Continental Diamond Tool Corporation Breaks Ground on Major Expansion Project, Creating Job Opportunities

Continental Diamond Tool Corporation (CDT), manufacturer of diamond and cBN grinding products, marked a significant milestone as it officially broke ground on an ambitious expansion project at its headquarters in New Haven, Indiana. This development was announced by Shane Vardaman, President of Sales at CDT, in a video statement, which highlighted the company's dedication to growth, customer service, and innovation.

The $6 million expansion, which will add 70,000 square feet to the existing facility, will bring CDT's headquarters to an impressive total of 200,000 square feet. This expansion not only extends CDT’s capacity for delivering technologically advanced solutions to its customers but also brings job opportunities for the local community. The additional space will facilitate the company's plans to broaden its product offerings and enhance its customer service capabilities. It is anticipated that approximately 60 jobs in manufacturing, engineering, and sales will be added over the next 18 months.

In his video statement, Shane Vardaman expressed gratitude for the support received from CDT's loyal customers throughout the company's 50-year journey. 

"2023 marks 50 years of excellence in superabrasives … and it's also been a year of incredible growth. I want to personally thank all of our customers for your unwavering support," Vardaman said. "Whether you're new to the CDT family, or you've been with us for decades — thank you for your trust and commitment. We look forward to a future of continued growth, dedication, and innovation."

The expansion project demonstrates CDT's commitment to advancing grinding technology and its mission to deliver top-quality products like grinding tools and services to customers. The additional space will enable CDT to enhance its offerings and meet the changing requirements of various industries.

In this video of the groundbreaking on the company’s YouTube channel, the public can witness this important milestone in the company's history:

News of CDT’s expansion was also featured in this article in The Journal Gazette of Fort Wayne, Indiana.

Mastering Precision Grinding with Diamond Rotary Dressers for Plunge Dressing

When it comes to precision grinding, achieving exceptional accuracy and control is paramount. One of the key techniques that enable this level of control is Plunge Dressing through the use of a precision diamond rotary dresser. In this blog, we will explore Plunge Dressing and the crucial role it plays in the high tech manufacturing industry. We will also take a step back in time to uncover the history of this essential tool.

Understanding Plunge Dressing

Plunge Dressing is a specialized method used in precision grinding requiring the tightest tolerance controls. The process involves “plunging” a precision rotary diamond dresser with the form of the finish part vertically into the grinding wheel. This approach allows for a mirror image of the part to be put into the grinding wheel which is then used to grind the finished parts to the highest levels of accuracy achievable.

The History of Plunge Dressing

Plunge Dressing, in its essence, is as old as precision grinding itself. It evolved alongside the broader history of abrasive tools and precision engineering, with the diamond rotary dresser as a key component.

The roots of Plunge Dressing can be traced back to the early days of industrialization when grinding processes were becoming essential for the production of precision components. As the manufacturing industry advanced, the need for higher precision, tight tolerances, and complex profile (geometry) control became apparent. This led to the development and refinement of techniques, including the use of the precision diamond rotary dresser or diamond dressing wheel, to enhance the grinding process.

Since 1984, Continental Diamond Tool Limited, then called Consort Precision Diamond Company, has been making precision Hand-Set “Sintered” Rotary Diamond dressers. In 1995, CDT LTD made waves with its development of an electroforming process that greatly reduced the process time for Reverse Plated Diamond Rotary Dressers. With these advances and revolutionary technology in both Sintered and Reverse Plated manufacturing methods, precision Rotary Dressers are now more affordable and accessible to a greater number of industries.

The Benefits of Plunge Dressing with a Diamond Rotary Dresser

Plunge Dressing with diamond rotary dresser, offers a range of benefits that make it a preferred choice in precision grinding:

1. Precise Profile Control: Plunge Dressing with a diamond rotary dresser enables the precise shaping of intricate profiles on workpieces. This level of control is invaluable in applications where tight tolerances and intricate shapes are required with tolerances of 1um or better.

2. Reduced Heat Buildup: The controlled plunge of the diamond rotary dresser results in precise truing and conditioning of the grinding wheel.  This is especially important for materials that are sensitive to heat, helping to prevent thermal damage and maintain workpiece integrity.

4. Consistency and Quality: Plunge Dressing with a diamond rotary dresser ensures consistency in material removal, resulting in a high-quality surface finish on workpieces. This consistency is crucial for producing precise components with minimal variation.

The Mechanics of Plunge Roll Dressing

Plunge roll dressing involves a specific mechanical process. Here's a glimpse of how it works:

1. Preparation: To start, the diamond rotary dresser is set up and aligned with the grinding wheel.

2. Vertical Movement: Then the dresser is moved vertically into the spinning grinding wheel. The depth of penetration is precisely controlled to ensure the desired material removal.

3. Material Removal: As the diamond rotary dresser engages with the grinding wheel, it removes material from the wheel's surface. This process allows for the desired profile or shape to be formed on the wheel.

4. Controlled Withdrawal: After the material removal process is complete, the diamond rotary dresser is withdrawn from the grinding wheel. This is done with the same level of precision and control to maintain the desired profile.

APPLICATIONS for Plunge Dressing with a Diamond Rotary Dresser

Plunge-style diamond rotary dressers find applications in many industries, such as:

Aerospace: In the aerospace industry, where precision and tight tolerances are paramount, plunge dressing with a diamond rotary dresser is used to shape critical components for aircraft and spacecraft.

Medical Devices: Plunge-style diamond rotary dressers are essential for creating intricate and precise components in medical devices to ensure their safety and effectiveness.

Automotive: This type of diamond rotary dresser is regularly employed to craft precision parts for the automotive industry, contributing to the performance and longevity of vehicles.

IN SUMMARY

In the world of precision grinding, plunge dressing with a diamond rotary dresser stands out as a technique that empowers manufacturers to achieve the highest levels of precision and quality. Its control and consistency make it an invaluable tool for industries where tight tolerances and intricate profiles are the order of the day.

Our Consort Precision™ line of Diamond Rotary Dressers offers versatility in design, with custom plunge form dressers available in sintered or reverse plated variants. The plated plunge form rotary dressers have the extra benefit of being able to hold tighter tolerances, where as Sintered Rotary Dressers can have shorter lead times and hold up better in rough environments. Both Sintered and Reverse Plated Rotary Dressers can be manufactured and shipped from our manufacturing facilities in either North America or Europe.

Celebrating 50 Years of Excellence: Continental Diamond Tool Corporation's Remarkable Journey

This October marks a truly momentous milestone in our journey - the celebration of Continental Diamond Tool Corporation's 50th anniversary. For half a century, we've been dedicated to pioneering excellence in superabrasive tool manufacturing, and this journey of growth and innovation has been nothing short of extraordinary.

1973: The Humble Beginnings

Our founder, Ray Viggiano, took the first monumental step in the fall of 1973 when he opened the doors of our first 4,500 sq. ft. building on Hartzell Street in New Haven, Indiana. Little did we know that this was the inception of a legacy that would span decades.

A Half Century of Innovation and Expansion

Over the years, we have accomplished countless milestones:

• 1973 Continental Diamond Tool Corporation is established.

• By 1974, production of Metal Bond Diamond and CBN products and Diamond Stationary Dressers ramps up, setting the foundation of our expertise in superabrasives.

• 1978 saw the launch of our Resin Bond product line, expanding our product range and capabilities.

• Fast forward to 1984-1985, we ventured into the Plated product line, diversifying our offerings to meet evolving industry needs.

• In 1988, we attended our first trade show, marking the beginning of our active presence in industry events and networking opportunities.

• During the 1990s, we experienced steady growth, fueled by a dedicated team of loyal employees. Many of them have been working at CDT for decades, contributing their expertise and commitment to quality and customer service.

• 1997 marked a significant expansion with the doubling of our Hartzell Street building's size to 20,000 sq. feet.

• In 2012, we underwent our third expansion, doubling the Hartzell Street building again to 40,000 square feet.

• 2014 was the year we proudly launched our Vitrified product line.

• 2015 brought another expansion, increasing our Hartzell Street building's size to an impressive 55,000 sq. feet.

• In 2016, we acquired Sierra Diamond, a manufacturer of Metal Bond tools in Auburn, California, expanding our reach and welcoming West Coast customers to the CDT family.

• The year 2017 was marked by the launch of our Resin Hybrid Bond products after months of dedicated research and development.

• In 2018, we solidified our global presence with the acquisition of Consort Precision Diamond Company Ltd., a leading manufacturer of Diamond Rotary Dressers in the United Kingdom. Additionally, we completed construction and moved into our brand-new 130,000 sq. foot manufacturing and office facility on Rose Avenue in New Haven, Indiana, setting the stage for our future.

• Another acquisition of diamond grinding products distributor Access Diamond in California in 2019 further increased CDT’s market share.

• 2019 also brought the first expansion of our Rose Avenue location, adding 15,000 sq. ft. to make room for our state-of-the-art Grinding Lab for research and development that opened in 2020. This space allows us to enhance product performance and spur innovation for customers in specific industry applications.

• Also in 2020, we acquired Jalsons International, a manufacturer, and supplier of Diamond Stationary Dressers, further expanding our capabilities and welcoming more customers into our extended family.

• The year 2021 witnessed our investment in robotic automation and the addition of a third shift at our primary manufacturing facility in New Haven, Indiana, to meet increasing customer demand.

• In 2022, we proudly launched the next generation of Hybrid Bond Technology with the specialized EVO line of custom grinding products for the Cutting Tool industry.

• 2023 has been a year of remarkable growth as we acquired Alpex Wheel Company in New Jersey, expanding our customer base on the East Coast. In line with this, Consort Precision Diamond changed its name to Continental Diamond Tool Limited, marking its growth as the European subsidiary of Continental Diamond Tool Corporation. We also began production of Diamond Rotary Dressers at the Rose Avenue location.

FROM PAST TO FUTURE

This year, 2023, is indeed a special one as we celebrate half a century of dedication, innovation, and excellence in superabrasive tool manufacturing. We're immensely grateful for the unwavering support of our employees, customers, and partners who have been integral to our journey.

As we commemorate this significant milestone, we reaffirm our commitment to pushing the boundaries of what's possible in superabrasive tools. Here's to the next 50 years of excellence and innovation! Thank you for being a part of our incredible journey.

The Science Behind Resin Bond Grinding Wheels: How They Work and Where They Excel

In the world of machining and precision grinding, engineers and manufacturers are constantly seeking ways to enhance efficiency and finish parts to increasingly tighter tolerances. A key player in this arena is the Resin Bond superabrasive grinding wheel. This remarkable technology has revolutionized the way hard materials are shaped and finished. In this article, we will look at the science behind Resin Bond grinding wheels, understanding how they work and why they excel in various applications.

Understanding the Basics

Before we dive into the intricacies of Resin Bond grinding wheels, it is essential to understand the core fundamentals that govern their operation.

1. Resin Bond: Resin is a polymeric (plastic) material that can be formed under specific conditions. At Continental Diamond Tool, our Resin Bond products are created using phenolic and polyimide resins, which are combined with conventional abrasives, superabrasives, and metal powders to form specific grinding structures. The thermosetting resins are the bonding agent that hold the abrasive materials (typically Diamond or CBN) in place. Once blended together, wheel compositions are “hot pressed” to specific sizes & shapes in special molds, and the resins are cured.  After hot pressing to near-net shape, they are machined to final dimensions and tolerances for customer use. Resin Bonds are highly regarded for their ability to provide a firm mechanical grip on abrasive particles, ensuring stability during the grinding process. It is this bonding, combined with flexibility of grinding structures, that allow for the customization required for efficient grinding of a variety of materials and applications.

2. Abrasive Material: Abrasive materials are used in grinding, cutting, and shaping processes to remove material from workpieces. They differ in terms of hardness, durability, and efficiency. Superabrasive materials are a special class of abrasive known for exceptionally high hardness, wear resistance, and cutting efficiency. The two superabrasive materials we use at Continental Diamond Tool are Diamond and Cubic Boron Nitride (CBN). Diamonds are ideal for grinding and cutting extremely hard materials like ceramics, glass, and precious stones, while CBN is used for grinding ferrous materials like steel and hardened alloys. When superabrasives are embedded in a resin matrix, it creates an incredibly effective cutting and grinding tool when compared with conventional abrasives like Aluminum Oxide and Silicon Carbide grinding wheels.

3. Wheel Structure: The arrangement of abrasive material and fillers within the resin matrix forms the wheel's abrasive surface. These abrasives can be designed in various shapes and concentrations, depending on the intended application. Variables like abrasive grain type, size, shape, concentration, bond type, porosity, wheel grade, and design are carefully engineered to determine the wheel's performance characteristics: its cutting ability, surface finish quality, heat dissipation, suitability for specific grinding applications, and more.

How It Works

Resin Bond superabrasive wheels are employed in a wide range of applications, from grinding high hardness materials to sharpening other Diamond or CBN cutting tools. For optimal efficiency, Resin Bond grinding wheels perform best with applications that are well-suited to the way these wheels interact with the workpiece.

1. Cutting Action: When a Resin Bond wheel is brought into contact with a workpiece, the Diamond or CBN abrasives on the wheel's surface come into play. Superabrasives are exceptionally hard, making them capable of cutting through even the toughest materials.

2. Heat Generation: As the wheel cuts through the workpiece, friction generates heat. Both Diamond and CBN are excellent thermal conductors, but Resin Bonds do not inherently conduct heat well. As a plastic, Resin Bond deteriorates at pretty low temperatures compared with other bonds. Its wheel performance is best when coolants and compositions are tailored for “dry grinding” applications. In applications where heat dissipation is a priority, Resin Bond formulations can be manipulated by adding conductive metals such as copper or aluminum to remove heat more efficiently.

3. Wear and Tear: Grinding forces erode equipment over time. Unlike traditional abrasive wheels that wear down quickly and require frequent dressing to stay effective, Resin Bond superabrasive wheels can be formulated to be self-dressing. As the abrasive diamonds wear, new grains are exposed, maintaining a consistent cutting edge throughout the wheel's life.

4. Edge Stability: Edge stability refers to a tool’s ability to maintain the sharpness and integrity of its cutting edge over time. The combination of the high hardness superabrasive with the strong mechanical bond of the resin binder provides excellent edge stability and sharpness, which makes for more efficient grinding. Good edge retention increases productivity and reduces cycle times through less frequent tool changes and consistent cutting performance. 

5. Performance: Precision tolerances and highly controlled surface finishes are where Resin Bond Diamond and CBN wheels really shine. Their remarkable capabilities in these areas are especially crucial in industries like optics, where the tiniest imperfection can lead to significant quality issues.

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The Master of Surface Finish

Here are the top 8 reasons why the unique characteristics of Resin Bond make it favored across industry applications that require fine surface finishes:

1. Uniform Abrasive Distribution: Resin Bond wheels are manufactured using a carefully controlled process that results in a uniform distribution of abrasive particles throughout the wheel. This uniformity ensures that the wheel removes material evenly across the workpiece, preventing irregularities in the surface finish.

2. Self-Dressing Properties: The self-dressing action of Resin Bond grinding wheels helps maintain a consistent cutting edge, which is essential for achieving a smooth surface finish.

3. Cooler Grinding: Diamond and CBN are already excellent conductors of heat, and resin bonds can be formulated with conductive metals to further aid in heat removal. This improved heat dissipation lessens the likelihood of thermal damage, such as metallurgical changes and micro-cracking, which negatively impact surface quality.

4. Flexibility and Conformability: Compared to Vitrified and Metal Bonds, Resin Bonds are relatively soft and flexible, which is advantageous for contour grinding and achieving intricate shapes. This flexibility allows the wheel to conform to the workpiece's surface, ensuring the consistent contact needed for a smoother finish.

5. Controlled Grit Size and Concentration: Resin Bond wheels can be precisely engineered with specific grit sizes and concentrations of abrasive particles to optimize for surface finish requirements. Finer grit sizes and lower concentrations typically produce finer surface finishes, such as those required by polishing applications.

6. Reduced Wheel Wear: As mentioned earlier, Resin Bonds wheels tend to maintain their shape and cutting efficiency over a longer period than conventional grinding wheels. This lower wear rate contributes to a consistent surface finish.

7. Minimized Wheel Loading: Resin Bond wheels are less prone to loading, which occurs when swarf or material being ground adheres to the wheel's surface. Loading can negatively impact the surface finish, but Resin Bond wheels tend to resist this issue, helping to maintain consistent performance.

8. Wide Range of Abrasive Options: Resin Bond wheels are compatible with a wide range of abrasive materials, including Diamond and CBN. By tailoring the abrasive to the specific material being ground, it further enhances fine grinding efficiency.

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Areas Where Resin Bond Excels

Resin Bond superabrasive wheels are among the most popular and widely used bond types for a number of other compelling reasons.

1. Versatility: These wheels can be tailored to suit a wide variety of applications, making them indispensable in industries as diverse as automotive, aerospace, medical,and electronics manufacturing.

2. Precision: The accuracy and precision achieved with Resin Bond superabrasive wheels are unparalleled. They produce intricate shapes and finishes with exceptional consistency.

3. Longevity: Thanks to self-dressing properties, Resin Bond superabrasive wheels have a longer operational life compared to conventional abrasive wheels.

4. Reduced Waste: The minimal wear on these wheels results in less material waste, making them an eco-friendly choice for many industries.

5. Reduced Downtime: Less frequent wheel changes and dressing requirements mean reduced downtime and increased productivity for manufacturing operations. Additionally, these tools dress easily for added convenience. 

6. Cost-Efficiency: Despite an initial higher cost compared to conventional counterparts, the longevity and efficiency of a Diamond or CBN Resin Bond tool often result in cost savings over time. 

7. Hybrid Variants: Hybrid bonds combine characteristics of different bond types. This is especially common with Resin Bond wheels. For example, a hybrid wheel might have a blend of resin and metal bonds to balance precision with heat dissipation.

The Bottom Line

Resin Bond grinding wheels are a testament to advanced materials science and engineering precision. Their ability to cut, grind, and shape materials with unparalleled accuracy and efficiency has made them indispensable in numerous industries, especially in high-precision production grinding applications of hard materials.

These versatile grinding wheels are employed in tasks ranging from centerless and cylindrical grinding to surface and creep feed grinding. They cater to materials as challenging as tungsten carbide, ceramics, and stainless steel, where precision and surface finish are paramount. Resin Bond wheels also excel in cutoff, roll grinding, tool and cutter, saw and knife sharpening, PCD grinding, and surgical tool blade sharpening applications, showcasing their adaptability across the spectrum of manufacturing and fabrication needs. Whether it's the intricate precision required for surgical tools or the robust grinding demands of hardened steel, resin bond grinding wheels are trusted companions for achieving exceptional results.

As technology continues to advance with hybrid bond types, it is likely that Resin Bond superabrasive wheels will play an even more significant role in the quest for perfection in machining and precision grinding. Their adaptability, accuracy, and longevity make them a driving force behind innovation in manufacturing processes and a cost-efficient grinding solution for many industries around the world.

The Story Behind Our Precision Grinding Solutions at Continental Diamond Tool Ltd.

At Continental Diamond Tool Limited, our 40 years of success has been built by delivering the finest custom Diamond Rotary Dressers available in the market. Also called Diamond Rolls, these tools are used extensively in a growing number of grinding operations to primarily facilitate the transfer of highly accurate repeated configurations onto components. What makes a Consort Precision Diamond Rotary Dresser stand out can be summarized in four key aspects: technology, expertise, process, and quality or product excellence. As we have expanded into other product lines, we bring that same commitment to every precision grinding product we produce.

Cutting Edge Technology

In a plunge-style dresser the Rotary Diamond Dresser is mounted onto a spindle of a drive unit which in turn is mounted onto a slideway arrangement that allows the formed periphery of the dresser to infeed into a grinding wheel, thereby transferring the desired shape into it. The form, or configuration, can then be 'ground' on to the component. Plunge dressers are especially accurate for precision grinding as there is no lost form or geometry due to machine movements. Plus, the dressers can be held to submicron levels of accuracy.

Traverse dressing is a grinding wheel dressing technique where the diamond rotary dresser traverses across the surface of the grinding wheel to create a specific profile or shape. Traverse Disc Dressers allow you the flexibility to make profile changes or dress in completely new profiles with the same tool, reducing down time for wheel change overs or roll changes.

INDUSTRY EXPERTISE

Such Industries as the Automotive and Aerospace as well land based Turbine Engine production units employ large quantities of Rotary Diamond Dressers. Typically, within the Aero manufacturing industry, such components as Turbine Blades and Nozzle Guide Vanes as well as Flap Actuating Shafts require their intricate features to be ground with grinding wheels that have been formed with Rotary Diamond Dressers. As can be seen reference is made on our following pages to the many applications within the automotive industry.

CDT Ltd. can offer expertise in the selection of the most appropriate type of Rotary Diamond Dresser by reference to the configuration required and to the grinding machine on which it is to be used. Basically, three processes are employed. Handset Sintered, Random Set Sintered and Reverse Plated. Within each of those categories, selection of diamond type and their placement into the periphery of the Rotary Dresser, plays a major part in determining its operational life and performance. Even before its establishment in 1984, the company’s principals and a large proportion of its employees had many previous years experience in the manufacture of Rotary Diamond Dressers. Bringing with them unique knowledge of the industry, CDT Ltd. — then Consort Precision Diamond — quickly established itself with this one product into the global market of prime and subcontract component manufacturers, earning the respect of competitors and customers alike.

AWARD-WINNING PROCESSES

In respect to the Reverse Plating technique, at Continental Diamond Tool Limited we are particularly proud of the fact that we have been awarded the accolade of winning the BOOST award in the U.K. in 1995 for the design and development of a high speed plating process which dramatically reduced previous lengthy plating times. This achievement gave us a competitive edge against alternative suppliers and satisfied the reduced lead times that customers continue to demand. In the same period, we gained the S.M.A.R.T 1995 award for the development of the electroforming process as an acknowledgement of the reduction in the process time employed in the manufacture of Reverse Plated Rotary Diamond Dressers. CDT Ltd. proudly holds the ISO 9001:2015 Registration Certificate for its Quality Management Systems.

A FOCUS ON PRODUCT EXCELLENCE

The Consort Precision name has become synonymous for outstanding quality and performance in Diamond Rotary Dressers. Since 1984, we have been perfecting the design, development, manufacture, install and maintenance of this advanced dressing technology. This long history with a singular focus has given us the unique ability to provide our customers with the best solution technology can offer. We have the engineering, design, manufacturing and staff resources to supply the highest quality Diamond Rotary Dressers available on the market. Our specialized experience ensures each product we supply is the optimum choice for each individual customer, however demanding and complex the configuration. If an application calls for traverse- or plunge-style rotary dressing, Consort Precision™ Diamond Rotary Dressers are the best tool for the job.

With investment from our parent company, Continental Diamond Tool Corporation, we have expanded our facility in Kinmel Bay to manufacture a wider range of superabrasive products and better cater to a global market. In 2021, an expansion of the Plating lab more than doubled our capacity to produce the high quality tight tolerance reverse plated rotary dressers used by some of the world’s most prestigious corporations. It also paved the way for diversification into electroplated grinding wheels, which we began producing in early 2023. As CDT Ltd. continues to evolve and adapt to the ever-changing technological landscape, we remain committed to delivering innovative solutions and superior products to meet the growing demands of our customers worldwide.

Mastering Precision: How Traverse Diamond Dressing Enhances Grinding Wheel Performance

Precision in manufacturing is the key to producing high-quality components across various industries, from automotive to aerospace, and even in everyday consumer products. One crucial aspect of achieving this precision is the performance of grinding wheels. In precision grinding operations, where the tolerances can be incredibly tight, grinding wheel performance is paramount. Enter the Traverse Diamond Dresser, a type of diamond rotary dresser that plays a pivotal role in ensuring that grinding wheels are in top form. In this blog post, we will delve into the world of Traverse Disc Dressers and explore how they enhance grinding wheel performance.

The Basics of Traverse Diamond Dressing

The Traverse Disc Dresser is an indispensable wheel profiling tool in the realm of precision grinding. Also referred to as Diamond Wheel Dressers, they are designed to dress and shape profile grinding wheels to maintain an optimal condition. The dressing process involves the removal of abrasive material from the grinding wheel's surface, which can become uneven, clogged, or worn over time due to the abrasive grinding process.

Here's how Traverse Disc Dressers work their magic:

1. Material Removal: These dressers feature a wide range of diamond sizes and grades to achieve the desired dressing condition. As the rotary diamond dresser traverses across the grinding wheel's surface, it precisely and efficiently removes small amounts of abrasive material. This effectively 'cleans' the wheel, restoring its cutting ability.

2. Wheel Truing: One primary function of Traverse Disc Dressers is truing the grinding wheel. Over time, grinding wheels can develop irregularities, affecting the precision of the grinding process. The dresser ensures that the wheel runs true and maintains a consistent, flat or cylindrical shape, depending on the application.

3. Form Dressing: In precision grinding, some applications require intricate shapes or profiles to be ground onto workpieces. Traverse Disc Dressers can be employed for form dressing, which shapes the grinding wheel to match specific profiles with utmost precision.

Achieving Superior Grinding Wheel Performance

Now that we understand the role of Traverse Disc Dressers let's explore how these wheel profiling tools enhance grinding wheel performance:

1. Consistency is Key: Precision grinding demands consistency. Traverse Diamond Dressing ensures that the grinding wheel profile remains uniform in shape, minimizing variations in the workpiece's finish and dimensions. This consistency is essential for meeting tight tolerances.

2. Optimized Material Removal: Dressing the wheel not only ensures precision but also optimizes material removal rates. It enhances the wheel's cutting ability, reducing heat generation and the risk of burning the workpiece—a common issue in precision grinding.

3. Reduced Scrap Rates: With a properly dressed grinding wheel, the likelihood of producing defective or out-of-spec parts is significantly reduced. This translates to lower scrap rates and higher yields, ultimately improving the bottom line.

4. Versatility: Traverse Disc Dressers are versatile tools suitable for various grinding applications. Whether you're grinding metals, ceramics, or other materials, these dressers can be adapted to meet your specific needs.

5. Flexibility: Change parts/profile shapes frequently?  Traverse Disc Dressers allow you to quickly and easily make profile changes or dress in completely new profiles without making grinding wheel changes, saving you down time for wheel change overs and/or roll changes.

Applications for Traverse Disc Dressers

Traverse Disc Dressers play a pivotal role in a multitude of precision-driven industries. These grinding wheel truers are essential for maintaining and shaping grinding wheels, ensuring that precision grinding processes yield consistent and accurate results. Here's a succinct overview of how key industries rely on Traverse Disc Dressers:

Automotive: Crucial for precision grinding in tasks like crankshaft and camshaft production, gear manufacturing, and engine component fabrication.

Aerospace: Used in grinding operations for aircraft components and jet engine parts, where precision is paramount.

Tool and Die Making: Maintains the sharpness and precision of cutting tools, including end mills, drill bits, and punches.

Medical Device Manufacturing: Ensures precision in the production of surgical instruments, orthopedic implants, and dental tools.

Bearings and Bearing Components: Shapes and maintains grinding wheels to ensure the accuracy of bearing components.

Cutting Tool Manufacturing: Essential for achieving precise tool geometries and cutting-edge profiles in tools like inserts and taps.

Oil and Gas: Involved in precision grinding for drilling equipment, pumps, and valves, vital in this sector.

Metalworking: Used in the production of gears, shafts, and machine components to meet precision requirements.

Die Casting and Foundry: Maintains and shapes grinding wheels to finish cast components with tight tolerances.

Renewable Energy: Supports precision grinding operations for components in renewable energy technologies like wind turbines and solar panels.

These industries rely on Traverse Disc Dressers for precision and consistency in their manufacturing processes, making them essential tools for achieving the highest levels of accuracy in precision grinding operations.

Types of Traverse Disc Dressers

Traverse Disc Dressers come in distinct types, each designed for specific applications. They can be made with a wide range of diamond sizes and grades, with CVD (chemical vapor deposition) stones, or a combination of the two, to achieve the desired dressing condition.

1. Electroplated: Electroplated Traverse Disc Dressers are known for their short lead times and open and aggressive structure allowing for high removal rates with similar performance at a lower cost.

2. Metal Bond: Metal bond Traverse Disc Dressers offer flexibility with a range of bond systems and abrasives to custom fit the application and provide a balance of durability and precision, making them suitable for a wide range of grinding operations.

3. Sintered: Sintered Traverse Disc Dressers offer exceptional durability and precision and are ideal for applications involving hard and abrasive materials with tight profile tolerances. 

4. Reverse Plated: Reverse Plated Traverse Disc dressers stand out due to their unique construction, which allows for unmatched precision and efficiency in shaping grinding wheels. They offer benefits such as reduced dressing time, extended wheel life, improved surface finish, and versatility, making them a valuable asset for industries requiring the highest levels of accuracy in their grinding operations.

It's worth noting that CDTUSA manufactures all types of traverse dressers except Reverse Plated, which will be added to our lineup next year. CDT Limited in Europe (previously Consort Precision Diamond) specializes in Reverse Plated, as well as the other types of diamond rotary dressers. When it comes to grinding wheel truers, our dedicated teams are ready to assist you. Feel free to reach out for a free quote, and let us help you achieve precision and excellence in your grinding operations.

Continental Diamond Tool Ltd. Earns Three Nominations for WCNW Chamber Recognition Awards

Continental DIamond Tool Limited (CDT Ltd.), the European subsidiary of Continental Diamond Tool Corporation, is excited to announce its nomination for three esteemed awards by the West Cheshire & North Wales Chamber of Commerce (WCNW Chamber). These nominations underscore CDT Ltd.'s dedication to excellence and innovation in the diamond tool industry.

The WCNW Chamber Recognition Awards celebrate businesses in the West Cheshire and North Wales region for their remarkable achievements and contributions to the local and international business landscape. CDT Ltd. is honored to be nominated in the following categories:

1. Award for Export & International Trade

This nomination acknowledges the strength of West Cheshire & North Wales exporters. Entrants must distinguish themselves on the international stage and demonstrate significant and sustained increases in export activity. CDT Ltd. takes pride in its global reach and commitment to delivering high-quality diamond tools worldwide, reinforcing its dedication to expanding its international presence.

2. Business Growth Award

Open to businesses of all sizes, this award recognizes organizations that have experienced remarkable growth in areas such as sales, profit, market share, job creation, and international trade. CDT Ltd.'s nomination underscores its unwavering commitment to growth, innovation, and excellence in all aspects of its operations.

3. Business of the Year Award

The pinnacle recognition for businesses in West Cheshire & North Wales, this award is open to companies of any size and sector. CDT Ltd. is proud to stand among other outstanding businesses, symbolizing its dedication to achieving the highest standards of performance, innovation, and corporate responsibility.

These nominations reflect the dedication and passion of the entire CDT Ltd. team. We extend our heartfelt thanks to our employees, customers, and partners for their unwavering support, which has played a pivotal role in our success.

Just last week, CDT Ltd. announced its name change from Consort Precision Diamond, aligning its identity and marketing efforts with its parent company, CDT Corporation. This strategic move comes as CDT Ltd. continues to expand its offerings in high-performance electroplated grinding technologies. You can learn more about this exciting change here.

As we eagerly await the awards ceremony in November, we express our gratitude to the WCNW Chamber for recognizing our efforts and achievements. We also extend our best wishes to all fellow nominees in these esteemed categories, as their accomplishments contribute significantly to the vibrant business community in West Cheshire and North Wales.

To discover more about the WCNW Chamber Recognition Awards and the remarkable businesses being celebrated, please visit this link. Stay tuned to our Linked In, Instagram, and Facebook pages for updates on our journey toward the awards ceremony, and join us in celebrating this momentous occasion.

At Continental Diamond Tool Limited (CDT Ltd.), we are committed to innovation, excellence, growth, and service toward our valued customers and partners worldwide. Thank you for being a part of our success story.

Consort Precision Diamond Company Announces New Identity As Continental Diamond Tool Limited

Kinmel Bay, Rhyl, U.K. (September 11, 2023) – Consort Precision Diamond Company, a top manufacturer of precision diamond tools in the United Kingdom, is pleased to share a major announcement. Effective July 10, 2023, the company has officially changed its name to Continental Diamond Tool Limited.

The new name aligns with its parent company, Continental Diamond Tool Corporation (CDT), which acquired Consort in 2018. With headquarters in New Haven, Indiana, U.S.A., CDT is recognized globally for manufacturing high-precision custom superabrasive grinding wheels, which integrates seamlessly with Consort as a distinguished and trusted producer of high-quality precision diamond rotary dressers.

At the core of this name change is a firm dedication to delivering premium quality and innovation. Over the past several years, the company has expanded its facility in Kinmel Bay to manufacture a wider range of superabrasive products and better cater to a global market. In 2021, an expansion of the Plating lab more than doubled the company’s capacity to produce the high quality tight tolerance reverse plated rotary dressers used by some of the world’s most prestigious corporations. It also paved the way for diversification into electroplated grinding wheels, which the facility began producing in early 2023.

This strategic growth is part of the company's unwavering commitment to delivering comprehensive solutions to customers. As the company continues to expand its offerings to encompass more high-performance grinding technologies in step with its parent company, aligning the name and marketing efforts of the two is a logical move. 

In the coming weeks, on-lookers can expect to see updates across various aspects of Consort's branding and materials as it transitions to Continental Diamond Tool Limited. This includes revisions to its packaging, marketing materials, website, and all pertinent documentation. The company is committed to ensuring a smooth transition, with minimal disruption to the customer experience.

“For nearly four decades, Consort has faithfully served leaders in the automotive, aerospace, and other precision manufacturing industries. We look forward to continuing our longstanding relationships with customers under our new name,” says Jeff Wirth, Managing Director of Continental Diamond Tool Limited. For further information about this transition, please send any queries to info@cdtltd.com.

About Continental Diamond Tool Limited

Continental Diamond Tool Limited is a globally recognized leader in custom precision diamond tools, specializing in all forms of precision diamond rotary dressers and electroplated grinding products. With a commitment to excellence and innovation, the company serves a diverse range of industries from its advanced manufacturing facility located in the coastal town of Kinmel Bay in Conwy County Borough, Wales, United Kingdom. Learn more at CDTLTD.com.

Understanding the Distinction Between CBN and Aluminum Oxide Abrasives

Are you ready to explore the fascinating world of abrasives? In manufacturing, we often encounter Superabrasives and Conventional abrasives. In the Superabrasives corner, we have Diamond and Cubic Boron Nitride (CBN), and their common Conventional abrasive counterparts are Silicon Carbide and Aluminum Oxide. Each serves a specific purpose. What makes CBN and Aluminum Oxide stand out is their exceptional ability to tackle those stubborn steels and metals that can't stand Carbon.

In this blog, we'll explore the properties and applications of CBN and Aluminum Oxide abrasives. Discovering their unique characteristics will help you choose the right abrasive for your specific machining needs, ensuring efficiency and top-notch results. Whether you're working with hardened steels or softer metals, the right abrasive is the key to achieving your desired outcome in grinding and machining. So, let's dive in and unlock the true potential of CBN and Aluminum Oxide abrasives.

What is CBN?

CBN is a synthetic Superabrasive known for its incredible hardness, high thermal conductivity, and thermal stability. Originally released with the trade name Borazon from GE Superabrasives, its cubic crystal lattice structure is similar to Diamond, giving it remarkable abrasive properties. With a hardness close to 10 on the Mohs scale, CBN excels in machining tough materials that require precision grinding. Its chemical composition and high thermal stability prevents chemical reactions and premature breakdown under high temperatures, when grinding ferrous metals and high-temperature alloys. What's more, because CBN doesn't react with ferrous materials, it doesn’t alter or change their properties resulting in longer life in use when ground with CBN.

CBN is a game-changer when grinding hardened ferrous alloys or super alloys that are sensitive to heat. It efficiently grinds hardened steels while maintaining accuracy and surface finish. Plus, it's a favorite for grinding ferrous metals like cast iron and stainless steel, ensuring clean and precise results without chemical alterations. CBN is a must-have tool for achieving precise and efficient outcomes in critical machining tasks.

What is Aluminum Oxide?  

Aluminum Oxide, also known as alumina, is a versatile Conventional abrasive. With high hardness and toughness, it is available in various grit sizes, making it perfect for a wide range of machining and finishing applications. Though not as hard as CBN, Aluminum Oxide is fantastic for soft metals, wood, and non-ferrous materials. While it may not match the precision of Superabrasives, it's still a reliable choice for many tasks.

In the machining industry, Aluminum Oxide is the go-to for grinding soft metals like aluminum, brass, and copper. It performs beautifully with non-ferrous materials such as bronze and titanium, without causing any chemical interactions. Its role in achieving desired surface finishes across various industries, from automotive to aerospace, is unparalleled.

Key Differences Between CBN and Aluminum Oxide Abrasives

While CBN and Aluminum Oxide both play significant roles in grinding and machining operations, they have many distinct properties that set them apart.

Crystal Structure and Hardness: CBN's crystal lattice structure is similar to Diamond, resulting in exceptional hardness and wear resistance. Aluminum Oxide, while still hard, has a lower hardness than CBN, making it more suitable for soft metals and certain alloys.

Heat Resistance and Thermal Conductivity: CBN exhibits superior heat resistance and thermal conductivity compared to Aluminum Oxide, making it perfect for grinding high hardness and heat sensitive alloys.

Material Compatibility and Reactivity: Both CBN and Aluminum Oxide are chemically inert with ferrous materials whereas Diamond and Silicon Carbide are not, thus why they are the abrasives for ferrous metals.

Cost and Practicality: CBN grain costs significantly more than Aluminum Oxide grain, resulting in higher grinding wheel prices. Because of higher hardness and better thermal conductivity, CBN wheels can provide lower grinding costs in applications where high workpiece hardness and thermal properties need to be maintained. In cases of grinding soft steels and low volume production, the lower wheel price of Aluminum Oxide makes it a more competitive option.

Safety Considerations and Handling

Whether you choose CBN, Aluminum Oxide, or another solution for your abrasive, ensuring safety during grinding and finishing processes is essential. Proper machine guarding, eye and respiratory protection, proper dust/mist extraction, and careful handling and storage of abrasives are crucial to protect workers and maintain a clean and safe work environment.

Selecting the Right Abrasive for Specific Applications

Choosing the right abrasive for your specific machining needs is vital to achieving optimal results. Making an informed decision will ensure efficient, accurate, and cost-effective grinding and finishing processes. Some factors to consider include:

Workpiece Material Characteristics: Soft metals like aluminum, brass, copper, and mild steels  may need moderate hardness abrasives like Aluminum Oxide to prevent excessive material removal, while harder materials like hardened steels and high-temperature alloys such as inconel and hardened Stainless Steel  require abrasives with superior hardness and high thermal conductivity like CBN for precise and efficient cutting and grinding.

Machining Operations and Efficiency: Superabrasives like CBN are preferred for high-precision tasks where tight tolerances and maintaining material properties are paramount, while conventional abrasives like Aluminum Oxide offer lower cost solutions for general grinding of mild steel and soft metals.

Surface Finish and Material Removal Rates: Superabrasives like CBN excel in production applications of hardened steels and Superalloys that are sensitive to heat, , while conventional abrasives like Aluminum Oxide are effective in low volume applications and for grinding of soft metals.  

Tooling and Machinery Considerations: Abrasive selection also needs to account for machinery and tooling capabilities.  The truing and dressing of Superabrasive and Conventional Abrasive grinding wheels can be different and require different tools (stationary or rotary dressers of different configurations).  Because of the difference in hardness between CBN and Alumina, Alumina being much lower, the amount of grinding debris resulting from wheel wear during grinding can be 100-300 x’s greater with the conventional wheel, which in turn needs to be disposed of.  .

Both CBN and Aluminum Oxide abrasives offer distinct advantages in grinding and machining. Considering their unique properties with specific application requirements will lead to efficient and precise processes, ensuring optimal results and safety in the workplace. And if you ever need assistance, our grinding experts at CDT are here to help. Whether it's Superabrasives or Conventional abrasives, we can help find the perfect solution for your process.

Superabrasive Grinding Technology for the Ceramic Industry

The rapid growth of ceramic and carbide components in industries such as Automotive, Aerospace, Medical, and Electronics has created new challenges for grinding professionals. The hardness, abrasiveness, and brittle nature of ceramics and carbides make them difficult to grind efficiently. Yet advancements in superabrasive grinding technology have paved the way for improved grinding processes and reduced cycle times for those that invest in new custom technology. In this article, we explore the transformative impact of custom superabrasive grinding products on the ceramics industry, highlighting the benefits they offer and the cutting-edge technologies driving these innovations.

Overcoming Grinding Challenges in the Ceramics Industry  

Ceramic and Carbide materials pose unique challenges when it comes to grinding due to their unique hardness and abrasive properties. Traditional metal bond and resin bond grinding wheels have been the go-to solution for grinding these materials. However, advancements in CNC grinding equipment and the introduction of new bond systems have revolutionized the way ceramic and carbide components are ground.

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In different industries like electronics, optics, aerospace, and advanced manufacturing, people are using carbide and ceramic coatings to make components last longer and better at handling heat. Two common ways to add these coatings are HVOF (High-Velocity Oxygen Fuel), which uses high-speed flames to spray the coating onto surfaces, and HVOC (High-Velocity Oxygen-Fuel Cold Spray), which works at lower temperatures with fast-moving gas. Another method is Chemical Vapor Deposition (CVD), where a thin layer of material is deposited on a surface through chemical reactions in the vapor phase. Using CVD or HVOF/HVOC can make components longer lasting and more wear resistant.

The inclusion of carbide or ceramic layers necessitates special consideration during the grinding process because of the inherent hardness and abrasive properties of these materials. Superabrasive grinding wheels offer superior performance in grinding these materials by reducing grinding forces, lowering power consumption, and minimizing subsurface damage. These innovative grinding products are particularly effective in reducing grinding cycle times and reducing scrap, resulting in significant cost savings and enhanced productivity.

Advances in Superabrasive Grinding Technology 

The advent of multi-axis CNC grinding with Rotary Dressers has automated grinding processes, increasing efficiency and accuracy. Spindle & High-Pressure Coolant systems have improved the delivery of coolant to critical grinding areas, optimizing swarf removal and improved the cooling and lubrication during the grinding process. High-speed grinding spindles enable a wider range of bond technology and wheel sizes to be used for ID and smaller part grinding.

New "Cutting Tool" designs, such as slotting, high porosity bonds, coolant holes, and CNC adaptors for improved rigidity, have improved tool life and performance. These designs enhance coolant flow, chip evacuation, and overall tool effectiveness, contributing to longer tool life and reduced downtime.

Innovative bond systems have been developed to address the unique challenges of grinding ceramic and carbide materials. These new bonds lower grinding forces, reduce power consumption, and lead to faster cycle times. They also minimize subsurface damage resulting in lower scrap rates while enhancing the quality and integrity of the finished components.

Superabrasive Grinding Products for Ceramic & Carbide Components

CDT's superabrasive solutions deliver significant benefits, including a reduction in grinding forces by 30% or more (compared with resin & metal bonds), reduction in cycle times by up to 50%, and significant reduction in scrap rates on these critical and costly components. These advancements help manufacturers optimize their grinding processes, increase productivity, and reduce costs.

Continental Diamond Tool (CDT), a leading provider of superabrasive solutions, offers a comprehensive range of grinding products designed specifically for the ceramics & carbide industries. Their products are compatible with major industry equipment manufacturers, including Studer, Kellenberger, Danobat, Walters, ANCA, Junker, Okuma, Koyo, USACH, Lapmaster, Peter Wolters, SpeedFam, Stahli, Supfina, and many more. CDT also offers advanced custom tool designs, such as cross cutters and hole drilling with flat bottom drills, to address specific grinding requirements. Their expertise extends to a wide range of equipment, including round tools for Anca, Haas, ITM, Normac, Rollomatic, Star, and Walters, as well as inserts for Agathon, Coborn, EWAG, Waida, and Wendt. Additionally, CDT has created surface grinders for Arter, BLOHM, Brown & Sharp, Chevalier, ELB, and Magerle, as well as Blanchard grinders for Blanchard, Bourn & Koch, and DCM.

Superabrasive grinding products have revolutionized the ceramics & carbide industry, overcoming the challenges presented by the high hardness and abrasive nature of these materials. With reduced grinding forces, faster cycle times, and reduced scrap rates, manufacturers can achieve greater efficiency, productivity, and cost savings. Continental Diamond Tool's advanced superabrasive solutions provide tailored grinding products for a wide range of equipment, enabling manufacturers to optimize their grinding processes and achieve exceptional results. As industries continue to evolve to use more ceramic & carbide materials, the use of superabrasive grinding products will undoubtedly play a crucial role in meeting the growing demand for efficient production of these components.

5 Common Questions About Industrial Diamonds For Grinding

1: What are industrial diamonds, and how are they used in grinding wheels?

Industrial diamonds can be either synthetic diamond or natural diamond and are specifically processed for industrial applications, rather than for jewelry. 

Industrial diamonds are used in grinding wheels as an abrasive that removes material from a workpiece through friction and cutting. When the grinding wheel rotates against the workpiece, the diamond particles (abrasives) efficiently remove small particles of the workpiece – resulting in geometry, size, and finish desired.

Because diamond is the hardest known material, grinding wheels with diamond abrasives are commonly used in hard material applications that require high precision and accuracy such as in the aerospace, automotive, medical and semiconductor industries. CDT has experience working with grinding operations in all of these areas.

2: How are industrial diamonds manufactured?

Natural diamonds have been used for a long time in industrial grinding. They are mined from the earth and transported to a plant for processing. Through a system that includes x-ray machines and hand sorting, the gem quality diamonds are separated from industrial diamonds. These small, lower-quality stones, otherwise known as ‘boart,’ can be used in equipment such as grinding wheels, drill bits, and dressing tools.

Synthetic industrial diamonds used in grinding wheels can be made in one of two ways: 

• High-pressure and high-temperature (HPHT) 

• Chemical vapor deposition (CVD) 

In the HPHT method, diamond-creating materials are put under high pressures and high temperatures to make it form into a diamond. In the CVD method, diamond-creating materials are put in a vacuum chamber where carbon gasses are then added to make it form into diamond. 

Whether naturally or synthetically sourced, the industrial diamonds are then crushed, milled, cut, shaped, and polished to customizable sizes and shapes. Then, the particles are bonded together to form a grinding wheel or cutting tool, typically using metal, resin, vitrified materials or electroplated in a single layer onto a metallic substrate. 

3: How do the properties of industrial diamonds affect the performance of grinding wheels?

Industrial diamonds are valued for their extreme hardness, wear resistance, and thermal conductivity. All of these impact the performance of a grinding wheel.

Extreme Hardness:

Diamonds are known for their extreme hardness because they are made up of carbon atoms that are held together in a cubic crystal lattice structure. You can think of it like a brick wall, where the precise arrangement and spacing of the bricks represents the arrangement of atoms in the cubic crystal structure. Like a brick wall, diamond is strong and stable, making it difficult to break or become deformed.

Because diamond is the hardest known material, it is not readily scratched by other materials. Instead, it does the scratching.  Because of the high strength of the carbon bonds, Diamond has the best wear properties of all abrasives unless chemically attacked by materials that react with carbon.

This gives grinding wheels the ability to precisely cut through and remove material from other hard substances like ceramics, glass and non-iron-containing metals with very precise geometries and dimensional tolerances. 

Wear Resistance:

A diamond's wear resistance refers to its ability to maintain sharp edges and cutting ability for longer, which results in longer-lasting grinding wheels that don’t need to be replaced as often.

Diamond particles can withstand high pressures generated during the grinding process – a crucial aspect of grinding that can cause other abrasive options to break down. Whereas the wear-resistant nature of a diamond abrasive maintains a durable, precise size and finish.

Thermal Conductivity:

Diamonds have the highest thermal conductivity of any known material, which is ideal for grinding due to the heat generated by the friction that occurs during the grinding process. Heat can cause abrasive particles in the wheel to become dull and less effective at cutting, as well as cause thermal damage to your workpiece.

Diamonds can conduct heat away from the grinding area more effectively than other abrasive materials. This keeps it cooler, protecting the material being ground from thermal damage and preventing the abrasive from becoming dull.

4: What are the advantages and disadvantages of using industrial diamonds in grinding wheels compared to other abrasive materials?

Advantages:

Diamond is the hardest known material due to it’s strong covalent bonds between carbon atoms and perfect crystal symmetry.  Because Diamond is harder than all other materials it is the best choice for grinding and wear resistance.  Other abrasives are softer than diamond and therefore do not last nearly as long.  Secondly, Diamond also has the best thermal conductivity and therefore removes/dissipates most effectively the heat generated during grinding.  

All of this makes diamond an advantageous choice as an abrasive because it will provide a longer-lasting durability, an improved precision, and a better quality finish.

Disadvantages:

Because of its high hardness, it also means that diamonds can’t be easily shaped or molded into different forms. Dressing of diamond wheels is done with Diamond tools, and with Diamond on Diamond, dresser life is low when compared with other abrasive types.  Secondly, Diamond grinding wheels are not recommended when grinding ferrous metals as a chemical reaction between Carbon (Diamond) and the metal is possible and results in changes of the material properties of the metal and premature wear of the Diamond grinding wheels, both of which can be detrimental.  Therefore, diamond is typically suggested for use in specialized applications for grinding of hard materials such as Ceramics, Carbides, and glasses.

5: What are the latest trends and advancements in industrial diamond technology for grinding wheels?

One of the latest trends in industrial diamonds is the increasing use of synthetic or man made diamonds. Diamonds that are grown in a lab are as real as diamonds mined from the earth. They are identical to natural diamonds in every way, except that they are created in a lab and the specific material properties of the Diamond can be tailored to specific applications..

As this process has gotten more efficient, man made diamonds can now be sourced cheaper and more readily than natural diamonds. Diamond grinding products are becoming more economically viable for a growing number of industries. CDT uses both natural and synthetic diamonds in its superabrasive products.   

Another advancement in industrial diamond grinding technology is the creation of hybrid bond grinding wheels. Hybrid wheels combine different types of bond to adhere the abrasive material, such as diamond, to the grinding wheel and achieve superior grinding performance. 

Traditionally, diamond grinding wheels use one of a handful of bonding agents to adhere the superabrasive material to the grinding wheel. Bonding options include:

• Electroplating

• Resin bond

• Metal bond

• Vitrified bond

Each of these bonding options have different characteristics which result in different pros and cons for the grinding process. You can learn more about the different bond types here. 

By combining bonds, hybrid wheels can be tailored to the needs of specific grinding applications, resulting in higher efficiency and reduced costs. CDT specializes in cutting edge, customizable hybrid bonds using diamond abrasives to provide superior results for our customers. You can learn more about our hybrid bonds here.

Industrial diamonds are a crucial component in many grinding processes, and they continue to play a vital role in the manufacturing industry. Because of their ideal thermal conductivity, wear resistance, and hardness, the technology will continue to advance to make the most use out of this favorable material. It is safe to say that industrial diamonds are not going away anytime soon, and their importance in the manufacturing industry will only continue to grow from here!

If you are wondering if diamond grinding wheels or tools would be a good fit for your specific application, contact CDT for a free quote. 

CDT Welcomes Alpex Wheel Company To The CDT Family

Continental Diamond Tool Corporation, a global leader in the manufacturing of Superabrasive grinding products, is proud to announce the newest addition to its business: Alpex Wheel Company.  Alpex Wheel Company, founded in 1954 in New Jersey, has a long-standing reputation of providing the highest quality superabrasive products and service. 

This addition brings exciting opportunities for both CDT and Alpex. CDT will benefit from Alpex's expert workforce and industry knowledge, while Alpex will now have access to CDT's extensive resources and technology, as well as CDT’s capabilities, innovations, and full array of products. 

Customers of Alpex can rest assured that CDT’s commitment to quality and service will remain. The company will continue to operate under its current management team and staff as operations transition to CDT’s global headquarters in New Haven, IN by the end of 2023.

This development is an exciting opportunity for both CDT and Alpex customers to benefit with over 100 years combined in the Superabrasive Industry, Alpex customers can expect a continuation of the highest quality Superabrasive products combined with the industry’s best customer service team.  

Continental Diamond Tool would like to thank the Baum family for their commitment to the superabrasives industry and wish them well in all future endeavors.  

CDT Expands Diamond Rotary Dresser Production

For companies in need of grinding wheel dressing, conditioning, and shaping, finding a high quality and cost effective supplier for custom dressing solutions is even easier!

Continental Diamond Tool is proud to announce that we’re expanding our capabilities to make custom Diamond Rotary Dressers (also known as Diamond Rolls) in our dressing product line.

Dressing tools are a necessary aspect of maintaining the natural wear and tear that occurs with superabrasive grinding wheels. When your abrasive becomes dull and ineffective due to particle buildup, it is recommended that you use diamond dressers to clear off the particles and make your grinding wheels perform like new again. 

While many tool and cutter grinding shops and other manufacturing facilities use stationary dressers to get that job done, more and more industries are finding uses for diamond rotary dressers — and for good reason!

As industries work with more and more advanced and complex engineering configurations, Diamond Rolls are the clear, superior choice for these applications … but why?

Simple. Diamond Rolls:

• Have precision profiles and geometry to match your specific needs

• Are designed for your specific needs, surface finish, removal rates, time savings

• Come in all shapes and sizes, from simple traverse dress rolls to complex profiles

Not only does it make way for excellent sharpening and fine finishes, it’s cost effective too.

CDT currently offers the following types of Diamond Rolls:

• CVD dressers

• Sintered Rotary Dressers

• Reverse Plated Rotary Dressers

Diamond Rotary Dressers are commonly used in the following industries:

• Aerospace 

• Automotive

• Biomedical

• Knives and Blades

• Bearing

Whether you are in an industry that’s looking for one of the dressing products above — or if you want to work with our engineers to develop something new— CDT is excited to serve your needs with the best possible up-and-coming technology for getting the job done right.

CDT has been in the business of providing solutions for sharpening and refinishing of superabrasive grinding wheels with Stationary Diamond Dressers since our start in 1973. In 2018, we added Diamond Rolls to our dresser line through our acquisition of Consort Precision Diamond in the U.K. who joined us with a solid reputation for making major technological advancements in rotary dresser technology. 

Now, after upgrades made in late 2022, Continental Diamond Tool has capabilities to produce many configurations of custom Diamond Rotary Dressers at our U.S. facility in New Haven, Indiana. Call us or complete our contact form for details.

How to Extend the Life of Your Electroplated Grinding Wheel

CDT offers what’s called the “Strip and Replate” Program, designed to give our customers the highest quality grinding wheel abrasives for the longest time possible, in the most cost effective way for the customer (more on this in a moment)...

First, let’s cover when you’ll want to opt for this program, and how it works.

Stripping and replating a grinding wheel refers to the process of removing the old, worn-out abrasive material from the surface of a grinding wheel and replacing it with new abrasive material.

When customers opt in for this program, we work with you to create customized tooling that you will be able to use and then bring back to CDT for us to return it to “like new” condition after it begins to wear. This keeps your wheel fresh and performing at optimal levels without having to buy new.

When To Strip and Replate?

There are many reasons why you may need to replace your wheel with new abrasive, including:

• The particles on the surface of your abrasive get clogged (potentially from metal shavings or debris from the grinding process)

• Your wheel becomes dull from the worn out abrasive

• You need to switch from grinding one material to another, and the new material requires a different type of abrasive to be put on your wheel

• The grinding wheel has worn down unevenly, causing vibrations and reducing your wheel’s effectiveness

How Does The Process Work?

CDT is able to provide high quality strip and replate services through strip technology that will remove the remaining abrasive on your worn down wheel without damaging the surface finish of the core.

Electroplating involves depositing a thin layer of metal and abrasive particles onto the surface of a grinding wheel by using an electrical current in an electrolytic plating solution. 

When a grinding wheel has reached its life, we remove the old abrasive material on your wheel by soaking the wheel in a chemical solution that will safely dissolve the deposited plating without damaging the integrity of the core. 

Once the old deposit and abrasive have been removed, we apply a new layer of abrasive material through the electroplating process.

After the new abrasive material has been applied, the grinding wheel is re-balanced to ensure you continue to have smooth operation and optimal performance with your returned “like new” wheel.

When is An Electroplated Grinding Wheel The Best Choice?

Electroplated grinding wheels are considered the superior choice for applications that require complex shapes or geometries. Some specific applications include metal cutting tools, saw and knife sharpening, PCD grinding, and surgical tool blade sharpening – among others.

They’re used in a wide range of industries, including metalworking, woodworking, glass and ceramics, aerospace, automotive, medical, and electronics manufacturing. 

Common materials that are compatible with an electroplated diamond grinding wheel include: 

• Cemented carbide

• Glass

• Ceramics

• Fiberglass

• Plastics

• And more

Whereas common materials that are compatible with an electroplated CBN grinding wheel include:

• Die steel

• Hardened carbon steels 

• Hardened stainless steels 

• Alloy steels

• Aerospace alloys

• And more

When you add in the ability to strip and replate, it makes electroplating a superior choice in many ways:

1. It provides a more consistent and uniform distribution of abrasive particles on the surface of your grinding wheel, which can help ensure consistent grinding results and prevent uneven wear in the future.

2. Electroplating creates a strong bond between the abrasive particles and the wheel substrate, which helps prevent the abrasive from separating or shedding from your wheel during use. 

3. It can be used to apply a wide variety of abrasive materials, including diamond, cubic boron nitride (CBN), and various types of abrasive grains – and it can be used with both brittle materials and soft metals.

4. Stripping and replating an electroplated grinding wheel is a relatively quick and straightforward process because they are a single layer wheel. It also allows for precise control over the thickness of the abrasive layer, making it an ideal choice for achieving any customizations you may need for your wheel.

5. Electroplated wheels can withstand heavy use and provide consistent grinding performance. They don’t need to be reconditioned as frequently as other types of grinding wheels, making them a more cost-effective choice in the long run.

Overall, opting for an electroplated grinding wheel to be reconditioned and used again through the CDT “Strip and Replate” Program can result in 40% more in savings, with consistent performance results, rather than opting for brand new plated products.

If you’re ready to learn how CDT can work with you for a customized electroplated grinding wheel that qualifies for our “Strip and Replate” Program, click the button below to request a quote!

The CDT technical team is ready to provide abrasive solutions to your questions that will increase your performance while reducing waste.

Survey Results Are In: CDT Delivers Unparalleled Customer Satisfaction!

At Continental Diamond Tool Corporation, we firmly believe that customer feedback is the lifeblood of our business. It is with great pleasure and enthusiasm that we present the astounding results from our recent customer survey. Your opinions and insights have not only validated our commitment to excellence but have also helped us identify areas where we can continue to improve. Join us as we share the key highlights from the survey and express our heartfelt gratitude to all the incredible customers who participated.

Quality That Exceeds Expectations

Quality 4.8/5

We are thrilled to announce that our CBN and diamond grinding tools have received an impressive average rating of 4.8 out of 5. This outstanding feedback showcases the superior quality and performance that our products consistently deliver. It is a testament to the meticulous craftsmanship and attention to detail that goes into every tool we produce. We are honored that our custom grinding tools have met and exceeded your expectations, and we remain dedicated to maintaining the highest standards of excellence.

Prompt and Reliable Delivery Service

Delivery 4.4/5

Time is of the essence in any project, and we understand the importance of delivering our diamond and cbn grinding products to you in a timely manner. With an average rating of 4.4 out of 5, our prompt and reliable delivery service has earned your appreciation. We recognize that delays can be detrimental to your operations, and we are committed to ensuring that your projects stay on track. Your satisfaction in this aspect of our service fuels our drive to continuously improve and optimize our delivery processes.

Knowledgeable and Responsive Customer Support

Customer Support 4.8/5

A strong and dependable customer support team is vital in providing a seamless experience. We are delighted to report that our customer support has received an impressive average rating of 4.8 out of 5. We take pride in our team's expertise and dedication to addressing your grinding wheel challenges and concerns promptly and effectively. Your positive feedback affirms that we are on the right track in providing the assistance you need, when you need it.

Impeccable Packaging and Presentation

Packaging 4.8/5

First impressions matter, and we understand that the packaging and presentation of our products play a significant role in your overall experience. With an average rating of 4.8 out of 5, our packaging has impressed our customers. We believe that every custom superabrasive grinding tool should arrive in impeccable condition and reflect the value and quality it holds. Your positive feedback motivates us to maintain our commitment to exceptional packaging and presentation standards.

Continental Diamond Tool Corporation as a Whole

Overall 4.6/5

The overall satisfaction rating of Continental Diamond Tool Corporation stands at an impressive average of 4.6 out of 5. This achievement is a testament to the dedication and hard work of our entire team. We are immensely grateful for your recognition and praise, and we are committed to continuously improving our services and products to provide you with an even better experience. Your satisfaction is our ultimate goal, and we will stop at nothing to surpass your expectations.

The results from our recent customer survey have filled us with immense pride and gratitude. The positive feedback and high ratings reflect the trust and satisfaction our customers have in Continental Diamond Tool Corporation. We extend our heartfelt appreciation to all the amazing customers who participated in the survey. Your feedback fuels our commitment to continuous improvement, and we promise to raise the bar even higher to exceed your expectations. Together, we will continue to shine as a leader in the grinding tool industry, delivering exceptional quality, service, and support.

Thank you for being an invaluable part of our journey towards excellence. We look forward to providing for your future superabrasive grinding needs. 

Contact us today for a free quote.

Meet The Next Generation In Hybrid Bond Technology: Ultra High Performance Grinding For The Cutting Tool Industry

At Continental Diamond Tool we are proud to announce that we have officially unveiled our latest breakthrough technology in hybrid bond products – the EVO Hybrid Bond – at the much anticipated Precision Machining Technology Show this past April 2023. 

What is EVO Hybrid Bond?

A game-changer in the precision grinding industry, EVO is a custom-designed bond that delivers ultra-high performance results that are impossible for our competitor’s standard Resin Bond wheels to match. 

This bond is a new and improved version of CDT's Resin Hybrid Bond, designed specifically to cater to the needs of Tool and Cutter Grinding.

One of the key benefits of EVO is its superior performance that helps produce high-quality cutting tools faster and more efficiently than its past versions. 

The bond is uniquely formulated to achieve faster cycle times without compromising on the wheel edge, making it an ideal choice for:

• Flute from solid

• Regrind

• Gash and end work

• And relief

What are the benefits of EVO Hybrid Bond?

When you opt for CDT’s EVO Hybrid Bond technology, you can expect superior results in both form retention and surface finish because of its free cutting action.

Additionally, the EVO bond is self-sharpening. This type of technology ensures the life of your wheel is longer-lasting, as is the dressing interval. 

It can also withstand much higher temperatures while still maintaining its stability, which makes high material removal rate not only possible, but incredibly precise.

Because CDT’s EVO Hybrid Bond offers excellent heat dissipation capabilities (while ensuring low and consistent power consumption) it enhances your overall efficiency and productivity of the grinding process.

It’s also a much more sustainable option. The wheel profile lends itself to a longer-lasting type of technology that reduces your grinding process costs in the long-term.

What sets EVO Hybrid Bond apart from the competition?

Beyond all of the benefits listed above, what sets EVO apart from other superabrasive grinding products is its unique blend of Resin Bond and Metal Bond. 

Available exclusively through CDT, this customizable type of bond is designed specifically to deliver cutting edge results that standard wheels cannot hope to compete with.

For the high precision cutting tool industry, EVO is a long-awaited solution to many common grinding challenges.

The bond offers a faster cycle time, less dressing, and greater performance. It is an ideal solution for those looking to improve their grinding process and achieve their goals.

At CDT, we are committed to providing the latest technology solutions to help the precision cutting tool community overcome their machining challenges. EVO Hybrid Bond is a testament to our commitment, and we are confident that it will transform your grinding process and help you stay ahead of the competition.

Haas Automation Machinery Features Continental Diamond Tool’s CNC Department

CDT is proud to have been recently featured by Haas Automation in their latest “Insider” video, showcasing the way in which our CNC department currently uses Haas machinery to produce high quality, customized results for our customers.

What does CDT’s CNC Department do?

The CNC department at Continental Diamond Tool (CDT) is responsible for using computer numerical control (CNC) machines to manufacture and grind diamond and CBN cutting and grinding tools. 

CNC machines use pre-programmed instructions to control the movement of tools and workpieces, allowing for precise and consistent manufacturing of complex parts and components.

In total, the CNC department supports 5 different aspects of CDT:

• Electroplated bonds

• Metal bonds

• Resin bonds

• Vitrified bonds

• Diamond rotary bonds

This involves using specialized tooling and fixtures to precisely machine and grind the wheel bodies, which are then bonded with diamond abrasive material to create finished grinding wheels.

The CNC department at CDT plays a critical role in ensuring the quality, accuracy, and consistency of our products, which is why using the proper machinery is so important.

Our CNC department frequently assesses the reliability and efficiency of all machines used to ensure that the quality and dependability of our product remains unmatched.

What HAAS machinery does CDT use?

CDT uses HAAS machinery at both our New Haven location as well as our facility in Europe. 

President of CDT, Nick Viggiano, says, “We bought our first 3 ST-10s about 12 years ago… Within around 3 months after that, we were purchasing a Mill and an ST-30 – and it continued to grow from there. Now we have close to 70.”

Haas offers ST-10s all the way up to ST-40s, which CDT has several of.

As far as Mills, CDT uses the VF8s, but uses some of the smaller ones as well.

Ron Fuller, Lead CNC Lathe Operator, says, “The greatest feature to me for my production rates and efficiency is the dual spindle aspect of these machines. It allows me to set the machine up and get it running and not have to stand there physically and operate the machine myself.”

The dependability of these types of machines allows the CNC team at CDT to streamline the grinding process for efficient and productive results. By not having to babysit machinery, time is freed to attend to other areas of the grinding process.

How does this type of machinery benefit the CDT customer?

Using Haas machinery is one part of many under the overarching CDT mission to provide exacting customizations for each of our customers' requests at the highest standards possible. 

By using machinery from Haas, as well as other reputable machinery producers, CDT is able to uphold this commitment.

The CNC team is committed to using the best machinery possible for each part of the process that will boost productivity and make it as cost effective for the customer as possible.

“Haas is one of many reputable machinery producers that CDT works with. They’re really great in supplying us with the tools we need to produce the high quality, customized products that our customers ask for.”

— Josh Werling, CNC Department Foreman

To learn more, check out the Haas “Insider” video below, and see how the CNC department at CDT uses these machines for different customization types.

Consort Precision Diamond To Participate In The LEAN Programme

Consort Precision Diamond, a leading manufacturer of precision diamond tools, is thrilled to announce its participation in the LEAN Programme! The LEAN Programme is an initiative that aims to help businesses in Wales achieve sustainable improvements in competitiveness. 

It is specifically designed for businesses that want to learn more about the principles of lean management, and is an intensive five-day programme that provides its attendees with a solid working foundation of both management principles and techniques. 

During the programme, participants learn how to: 

• Identify and eliminate waste

• Improve processes

• Increase efficiency

• And engage and empower employees to be more active participants in their roles 

All the subjects offered above are possible due to the collaboration between the Welsh Government and the Toyota Lean Management Centre in Deeside. The principles are taught through a mixture of: 

• Classroom theory

• Immersive shop floor observation

• Examples of practical application - all delivered at Toyota’s Deeside engine facility

• And worksite coaching at participant company sites to support productivity improvements

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"We’re really excited to be participating in this programme, and to have that opportunity to learn from some of the best in the industry," says Justin Hughes, one of the two employees from Consort who will be attending the programme. "This is a great opportunity for us to improve our productivity and competitiveness, and we are looking forward to applying what we learn to our work at Consort.”

Gareth Clifton, the other employee attending the programme, agrees. "We are very grateful for the chance to participate in this programme," he says. "This is definitely something that will not only help us improve our general skills and knowledge, but also contribute to the growth and success of Consort as a company, and that’s something we are always striving for. Can’t wait to hit the ground running when we come back from this experience."

At the end of the programme, participants will have a clear understanding of how to apply these principles to their own businesses. They will be able to implement sustainable improvements in the company’s productivity and competitiveness. 

In addition, they will have the opportunity to network with other participants during the 5-day event and learn from their experiences, as well as receive ongoing support from the Toyota Lean Management Centre to help them continue to improve their business. 

Consort has signed up to take part in the next available LEAN Start Programme, which is scheduled to begin in May 2023. 

As a subsidiary of CDT, Consort is committed to delivering the same high-quality products and services to its customers as CDT. The LEAN Programme is an important step towards achieving that ongoing expectation for growth, and we wish Justin Hughes and Gareth Clifton the best of luck at this programme!

Consort is looking forward to applying the principles and techniques learned from the programme to drive continuous improvement within the company. In doing so, it will continue to put Consort and CDT on the map as the highest-quality, highest-performing company for our customers to continue receiving exceptional results when they choose us for their project needs.

We cannot wait to continue serving you to the highest possible degree!

To learn more about this unique programme by the Toyota LEAN Management Centre, click here.

How To Select The Right Bond Type

Congratulations! If you are on this website, you’ve probably come to the conclusion that a superabrasive grinding wheel will be the best solution to your project’s needs. If you are still considering the pros and cons of the different types of grinding products, check out this article that explains the differences between superabrasive and conventional grinding wheels. 

Once you’ve decided you need a superabrasive solution for your grinding application, what’s the next step? 

SELECTING YOUR BOND TYPE

The bond acts as the glue that keeps the abrasive grains in your grinding wheel connected. The bond's strength, also known as its hardness, determines how well the wheel can handle different materials. 

Harder bonds are typically recommended for softer materials and vice versa. There is also the option to create custom hybrid bonds that are specially formulated to possess unique characteristics that will better support your more specific needs.

A grinding wheel expert can help you narrow down your selection, as there are many different bond types.

Let’s go over the common ones:

• Resin Bond

• Metal Bond

• Vitrified Bond

• Electroplated Bond

• Hybrid Bond

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RESIN BOND

Resin bonds are the most widely used bond type in superabrasive grinding wheels. Simply put, they are grinding wheels held together with a plastic bond.  They are made from synthetic resins, such as phenolic or epoxy, which is used to hold the abrasive in place. 

Mostly, these types of grinding wheels are formulated and blended as powders which are then cast and hot pressed in steel molds of the desired size and shape of grinding wheel desired.  The specific properties of the bond are determined by the specific resin and additives to get the desired mechanical and grinding properties.

Because of Resin Bond’s resilience and toughness, these grinding wheels tend to be:

• Easy to use

• Versatile across a broad range of materials & applications

• Relatively inexpensive when compared with other superabrasive grinding wheels

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METAL BOND

Metal bonds are, as the name suggests, made from metals – such as bronze and iron. Like Resin Bond products, Metal Bond grinding wheels are blended as powders and hot pressed in high temperature alloy or graphite molds as the processing temperature is much higher than resin.

Metal bond is the hardest of the bond types. Because of this, most Metal Bond grinding wheels are made with diamond, the hardest superabrasive, and are used on especially hard materials such as glass, ceramics, and carbides. Between the inherent hardness of the bond and the hardness of the materials being ground, these wheels generate the highest grinding forces and usually require special dressing or conditioning steps during use.  

Benefits of Metal Bond grinding wheels include:

• Resistance to wear

• Longest wheel life

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VITRIFIED BOND

Vitrified (or more appropriately known as “glass” or “ceramic”) bonds are different from resin and metal bonds in that they have both a mechanical bond like the others, but also a chemical bond between the abrasive (either dIamond or CBN) and the bond itself.  Most commonly, these bonds are engineered with porosity and are “cold pressed” and sintered as opposed to hot pressed.

While the actual glass/ceramic bond is technically harder than metal bonds, the porosity levels make the function better in grinding as the porosity efficiently removes grinding debris (swarf) and brings coolant into the point of grinding. Because of the porosity of these grinding wheels, they are also more readily able to be dressed and formed into specific desired geometries.

Because Vitrified bonded grinding wheels have lower grinding forces and the ability to be readily dressed with rotary dressers, this type of bond is ideal for high volume production grinding applications of hard materials that can most benefit from the:

• Lower grinding forces

• Faster grinding cycles 

• Lower scrap rates

In the case of CDT’s VIPER Vitrified Bond grinding wheels, we have enhanced the bond strength over traditional Vitrified Bonds, coupled with a porous vitrified structure, to more perfectly grind some of industry’s hardest materials like silicon carbide, aluminum oxide, glass, carbide, and others. Our VIPER Bond system provides enhanced dressability, lower grinding forces, and shorter grinding cycles over traditional Vitrified Bond systems.

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ELECTROPLATED BOND

An electroplated bond is a metallic bond (typically nickel for superabrasive grinding wheels) in which a single layer of abrasive is adhered or bonded onto a metallic core through a deposition process.  Like all electroplating processes, metallic material is pulled from solution and deposited onto the substrate, encapsulating the abrasive onto the substrate in the same form as the substrate.

Like the other bond types, both diamond and CBN superabrasives are used depending on the application.  Because electroplating is a liquid process, complex shapes and geometries are more readily achieved and generally don’t require dressing when in use.

Another benefit to using electroplated grinding wheels (also referred to as just ‘plated grinding wheels’) is that they are single layer and used wheels are able to “stripped” or reverse plating process and the substrate/core can be reconditioned and used again resulting in potential savings of as much as 40% over new plated products.

To recap, Plated grinding wheels:

• Generally don’t require dressing

• Can be designed in complex shapes and geometries

• Can be reconditioned and used again for cost savings over the life of the wheel

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HYBRID BOND

A hybrid bond is a combination of two or more different types of bonds and/or processing methods to create a “Hybrid” that encompasses enhanced properties to achieve better performance in grinding for a specific application.

For example, resin and metal bonds have successfully been combined into a single wheel in our EVO Hybrid Bond grinding wheels designed for the cutting tool industry. In this hybrid resin/metal bond wheel, the hard metal bond is softened to make it more user friendly while maintaining long life.  

New hybrid bonds and technologies continue to be developed to bring enhanced grinding performance to specific production grinding processes.

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NEXT STEPS

To dig deeper into why different types of materials require different grinding solutions, check out our previous blog Why Different Materials Need Different Grinding Wheels.

Grinding is a complex process that requires a total “systems” approach. Your grinding solution needs to encompass; the grinder/machine, dressing/truing requirements, material, coolant, and the grinding wheel. 

If you’re ready to move forward with a quote or investigate the advantages of a certain bond type for your specific application, contact us to speak with our team of expert engineers that will help answer your questions and get you started.