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abrasivetechnologySetting the global standards for superabrasive tooling™®
FOR PRECISION DRESSING, MACHINING, AND DRILLING
SUPERABRASIVE TOOLING & ACCESSORIES
THREE DECADES OF SUPERABRASIVE EXPERTISE
• Founded in 1971 in Worthington, Ohio, USA.
• 10 locations in 5 countries – USA, UK, Spain, Singapore and Canada.
• Process-Centered organizational structure for continuous improvements incustomer communications, product quality, delivery and cost.
• Steering Committee with a combined 80+ years of industry and leadershipexpertise.
Built on a solid entrepreneurial foundation, Abrasive Technology was founded in1971 by a young engineer and three others with a single product line. From thesebeginnings, AT has grown into a worldwide leader in superabrasive grinding andtooling with manufacturing locations around the globe. Abrasive Technology iscommitted to growing this worldwide presence through a balanced combination ofnew product development, product enhancement and new market opportunities.Integral to this growth is our Process-Centered organizational structure. This struc-ture facilitates continuous dedication to superior delivery and reduced costs, aswell as excellent communications and service to customers and distributors.Uniquely positioned to serve a diverse industry base, Abrasive Technology todaymanufactures a multitude of custom-engineered and in-stock products.
Abrasive Technology World Headquarters in Lewis Center, Ohio USA
BASIC DRESSING APPLICATIONS
APPLICATION TOOL TYPE
Dressing straight grinding wheels Single-Point Dressing ToolSimple profiles, thread and gear grinding
Straight and profile dressing Profile/Blade Dressers
Large OD wheels, surface and centerless wheels Multi-Point/Impregnated Dressers
Angle, radius and profile dressing Chisel & Cone Profile Tools (Plain & Diaform Style)
Custom designed to meet grinding profile requirements PCD Form Dressers
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DRESSING TOOLS
INTRODUCTION - DIAMONDS & DRESSING TOOLSNatural diamonds are available in many shapes: octa-hedrons, dodecahedrons, flats, elongated shapes, tri-angular, irregular shapes and grits.
Diamond qualities vary from the finest pure crystals,free from flaws, cracks or impurities, to the lowest grade crystals whichcan be considerably flawed.
Abrasive Technology’s customer service associates have years of expe-rience to help you choose the best diamond types and quality to matchyour tooling needs. We also have highly qualified design engineers tocustom design a tool to fit your exacting requirements.
DIAMOND GRADES
APPLICATION RECOMMENDED
For hard wheels or when very fine finishes and close tolerances “A” quality – 4 resettable pointsare required, such as thread, bearing and gear grinding
For demanding requirements and close tolerance work “B” quality – 3 resettable points
For average grinding conditions “BC” quality – 2 resettable points
For general purpose work, still resettable “C” quality – 1 resettable point
For general purpose work, non-resettable “NR” Non-Resettable
Diamond size = Diameter of wheel (D) + Width (W)10
Diamond size = Diameter of wheel (D) + Width (W)7
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DRESSING TOOLS
Grit sizeRev/Min 36 46 60 80 100 120 150 180 220
500 6-10 8-15 12-20 18-30 24-40 30-50 35-56 40-60 50-80750 4-7 6-10 8-13 12-20 16-26 20-33 27-42 30-45 38-60
1,000 3-5 4-8 6-10 9-15 12-20 15-25 18-28 20-30 25-401,250 2-4 3-6 5-8 7-12 10-16 12-20 14-22 16-24 20-321,500 2-3 3-5 4-7 6-10 8-14 10-17 12-19 13-20 17-271,750 1.5-3 2.5-4 3.5-6 5-9 7-12 9-14 10-16 11-17 14-232,000 1.3-2 2-4 3-5 4-8 6-10 8-12 9-14 10-16 11-172,500 1-2 1.5-3 2.5-4 3.5-6 5-8 6-10 7-11 8-12 10-162,750 1-2 1.4-2.8 2-3.5 3-5.5 4-7 5.5-9 6-10 7-11 9-153,200 .9-1.7 1.3-2.6 1.7-3 2.6-5 3-6 4.5-8 5-9 6-10 8-133,600 .8-1.5 1-2 1.5-2.5 2.3-4 2.5-5 4-7 4.5-8 5-8.5 7-12
1. MOUNTING THE DRESSING TOOL• Mount the tool with minimum overhang to avoid vibration.• Never mount a dressing tool in an oversized hole.• Mount the diamond with a 10 to 15 degree drag angle pointing in
the direction of wheel travel. When a straight dressing fixture ismounted on the table, position the diamond point past the center.A diamond pointing to the center of the wheel will cause vibrationand shorten the tool life. (Figure 1)
2. COOLANT• Dress dry when grinding dry. Dress with coolant if it is used during
the grinding cycle.• Do not turn the coolant on if the dressing cycle was started dry.
The thermal shock may fracture the diamond.• Direct a generous flow of coolant to the diamond at all times.
3. OPERATING PARAMETERS• Start the dressing cycle in the center of the wheel. (Figure 2)• TRAVERSE RATE: See chart below.• INFEED: 36 - 60 grit whl .001" (.025mm) to max .002" (.05mm)
80 - 180 grit whl .0005" (.013mm) to max .001" (.025mm)220 grit and finer .0002" (.005mm) to max .0005" (.013mm)
• INDEX THE DIAMOND DRESSER FREQUENTLYWhen the diamond wears, the increased contact area will generatemore heat and shorten the tool life. Index the dresser 20 to 30degrees when the wear flat reaches 1/16" (1.6mm). The diamond willthen develop a conical wear pattern. (Figure 3)
• RESET THE DIAMOND BEFORE A 3/32" (2.4mm) FLAT DEVELOPS
FOR “SG” WHEELS: Reduce infeed rate by 50% and increase the tra-verse rate. Use good quality diamonds with a sharp point.
RECOMMENDATIONS FOR SINGLE-POINT DRESSERS
CHART OF TRUEING TIME IN SECONDS PER INCH*(Lower figures for open wheel—Higher figures for finish)
INSTRUCTIONS1. Check the spindle speed.2. Go to the corresponding grit size column.3. Multiply the indicated seconds by the width of the wheel.4. The lower figure applies to dress an open wheel.5. The higher figure results in a finer finish.EXAMPLE. For a 36” x 4" (91.44cm x 10.16cm) 46 grit wheel run-ning at 500 RPM, the dressing time will be 8 seconds x 4 = 32seconds to dress an open wheel, 15 x 4 = 60 seconds to dress forfiner finish.These calculations assume that a relatively sharp diamond isused.
4. TRUEING TIME CYCLE• To calculate the trueing cycle, determine:
– The grit size of the grinding wheel.– The speed of the grinding wheel.– The width of the grinding wheel.
• To dress an open structure and aggressive grinding wheel, the dia-mond should not hit each abrasive grain more than once per revolu-tion. Therefore, grit size and wheel speed will determine traverse rate.
• To achieve a better finish, slow down the traverse rate to hit eachgrain a maximum of 2 times per revolution. If the traverse rate is tooslow the diamond dulls the abrasive and the grinding wheel will bur-nish and cause heat checks.
10º - 15º
1) General purpose dressing applications
2) Severe dressing applications
RIGHT WRONG
PROPERLY USED IMPROPERLY USED
Figure 1
Figure 2
Figure 3
Correct
Properly used Improperly used
Incorrect
*To convert trueing time into seconds per centimeter, divide table value by 2.54.
6
SINGLE-POINT DRESSING TOOLS
Straight Shank
Hand Dresser
Plain Headed Shank
Hexagon HeadedShank
Taper Shank
Plain HeadedTaper Shank
Hexagon HeadedTaper Shank
Threaded Shank
Chisel Shank
Taper HeadedShank
Magazine Dresser(Non-Resettable)
Turnable Head Dresser
Location Flat
Recess for Location
Recess for PointLocation
Partially Threaded
Totally Threaded
Internal Thread
Double Ended
Extraction Hole
Cranked Head
Screw Driver Slot
Tapered Head for Coolant
Coolant Slots
SHANK DESIGNS
All the above shank designs are available in Resettable and Non-Resettable formats.
TO DRESS CONCAVE RADII
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SINGLE-POINT DRESSING TOOLS
• Toolroom grinders• O.D. and surface grinding wheels
up to 18'' x 3'' (4500 x 750mm)
To Dress RadiusInch mm Inch mm.010 .254 .032 .813.015 .381 .062 1.574.020 .508 .125 3.174.025 .635
DimensionsA B C
Inch mm Inch mm Inch mm1/16 1.59 1/2 12.70 1/8 3.171/4 6.35 1 25.40 3/8 9.521/4 6.35 1 3/16 30.15 3/8 9.527/16 11.10 1 3/32 27.79 – –7/16 11.10 1 1/8 28.57 – –7/16 11.10 1 5/8 41.27 – –
HOW TO ORDERTool specs:1. Design/description of tool shank (See pg. 6) 4. Size of diamond2. Shank size 5. Dimensions of wheel to be dressed3. Quality of diamond (See pg. 4)
RESETTABLE & NON-RESETTABLE SINGLE-POINT DRESSERS
PRECISION DRESSING TOOLSFOR THREAD GRINDERSDressing tools for thread grinders require very sharp crystals. Theyare center set to .003" (.076mm) T.I.R.
B
A
B
A
FOR INTERNAL GRINDERSHEALD STYLE
A
B
Diamond is center set to .002" (.051mm) T.I.R.
Dodecahedron diamonds are center set towithin .004" (.1mm) T.I.R.
A
B
C
B
A
BRYANT STYLE
JONES & LAMSON STYLEA
B
C
A
B C
40° FLATS
• Very hard wheels• SG wheels• Thread or gear grinders
• Burr grinding wheels• Centerless regulating wheels• General purpose work
• Profile grinders• To dress small internal
grinding wheels
Recommended Non-Resettable Applications Recommended Resettable Applications
Diameters of 1/4” (6.3mm) to 3/4” (19mm), up to 6” (150mm) long.
DimensionsA B
Inch mm Inch mm1/4 6.35 1 25.401/4 6.35 2 50.80
DimensionsA B C
Inch mm Inch mm Inch mm1/4 6.35 11/16 17.46 3/8 9.527/16 11.10 1 25.40 – –
Natural diamonds center set to .003" (.076mm) T.I.R.
DimensionsA B C
Inch mm Inch mm Inch mm3/8 9.52 3 76.20 1/4 6.35
º
“R” RAD
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PROFILE/BLADE DRESSERS
RANGE: Small carat weight (0.4 - 2 carat).DIMENSIONS: Between 10mm (.379”) and 20mm (.787”) width.APPLICATION: • High wear applications
• Dressing large wheels
PLEASE STATE • Shank dimensionsWHEN ORDERING: • Wheel type
• Wheel size (diameter and width)• Grit size and type
L
D
W .394” - .787” (10 - 20mm)
Aº (0 - 45) All purpose forming tool suitable for all but very fineforms. These blades contain 2 or 3 layers of selectedlong diamonds.
Types Center Set BladesSide Set Blades
FADimensions of thediamond platePC2 X = 10mm (.379”)PC4 X = 15mm (.590”)
FBDimensions of thediamond platePC1 X = 10mm (.379”)PC3 X = 15mm (.590”)
A
B
E
D
30º
D
x
20ºC
30º
20º
x
A
B
E
D D
C
30º
x
A
B
E
D D
C
30º
x
A
B
E
D D
C
*Shown above are standard sizes. Contact customer service for full range. This product is also available in synthetic diamond.
FIXED BLADE DRESSERS
STANDARD REPLACEMENT BLADE DRESSERS*
Blade Dressers are available in fixed and swivel formats• Precision Profile tools are a cost effective alternative to expensive shaped single-point diamond tools.• Achieve close tolerance profile and finish.• Available in high quality graded natural diamond grits or hand set needle shaped diamonds.
Inch mmA 13/16 20.5B 25/32 20C 1/4 6.1
Inch mmD 3/16 5E 9/32 7
Inch mmA 29/32 23B 25/32 20C 1/4 6.1
Inch mmD 3/16 5E 9/32 7
Inch mmA 13/32 10.5B 13/32 10C 1/4 6.1
Inch mmD 3/16 5E 9/32 7
Inch mmA 1/2 13B 13/32 10C 1/4 6.1
Inch mmD 3/16 5E 9/32 7
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IMPREGNATED DRESSERS
FOR WHEELS 20" X6" AND SMALLER (500mm X 150mm)x
Small diamonds are carefully screened and are randomly spaced in anabrasion resistant matrix.
WHY THEY SAVE MONEY:• Diamonds can be completely consumed, nothing is wasted.• Longer tool life. Tool wear is shared by many small diamonds.• Less downtime because of shorter dressing cycle.• Fewer dressing passes saves wheel wear.
A E
D
C
B 15º
15°A E
D
B
C
A E
D
B
C
A
D
C
B
A
D
C
B
FOR WHEELS 10"AND SMALLER (250mm)
RECOMMENDATIONS:• Traverse rate: 25 IPM (.06M/min) and faster.• Infeed: .002” (.05mm).
• Start the dress in the center of the wheel.• Use flood coolant.
15ºA
B
E
C
D
C
D
EA
B
FOR WHEELS 20" X6" AND LARGER (500mm X 150mm)
SPECIFICATIONS:Crown - 1" x 5/8" x 1/8"
(25.4mm x 15.9mm x 3.2mm)
Shank - 7/16" x 1 5/8" OAL(11.1mm x 41.3mm)
RECOMMENDATIONS:• Traverse rate: 30 IPM
(.76M/min) and faster.• Infeed: .001" to .002"
(.025mm to .05mm).
• Use flood coolant.These are starting feedsand speeds and may needadjustment to suit the partspecifications. The tool re-quires periodic indexing.
FOR WHEELS 12"AND LARGER (300mm) CROWN DRESSER
IMPREGNATED DRESSERS
1B-6-D-7 2A-4-E-7 2A-4-D-7(54 to 100 grit) (46 grit & coarser) (46 grit & coarser)
1B-8-D-7 2A-6-E-7 2A-6-D-7(120 grit & finer) (54 grit & finer) (54 to 100 grit)
2A-8-D-7(120 grit & finer)
1R-6-J-7 2R-6-K-7
2B-4-A-7 1A-4-C-7 1A-4-A-7(46 grit & coarser) (46 grit & coarser) (46 grit & coarser)
2B-6-A-7 1A-6-C-7 1A-6-A-7(54 to 100 grit) (54 to 100 grit) (54 to 100 grit)
2B-8-A7 1A-8-C-7 1A-8-A-7(120 grit & finer) (120 grit & finer) (120 grit & finer)
Inch mmA 1/2 12.7B 3/8 9.52C 7/16 11.11D 3/4 19.05E 1/4 6.35
Inch mmA 1/2 12.7B 3/8 9.52C 7/16 11.11D 3/4 19.05E 1/4 6.35
Inch mmA 1/2 12.7B 3/8 9.52C 7/16 11.11D 3/4 19.05E 1/4 6.35
A E
D
15º
C
B
E
D
C
B
x
Inch mmA 3/8 9.52B 3/8 9.52C 7/16 11.11D 2 1/2 63.5
Inch mmA 1/4 6.35B 1/4 6.35C 7/16 11.11D 2 50.8
Inch mmA 3/4 19.05B 3/8 9.52C 7/16 11.11D 15/16 23.81E 1/4 6.35
Inch mmA 3/4 19.05B 5/16 8.26C 7/16 11.11D 15/16 23.81E 1/4 6.35
Inch mmA 3/4 19.05B 5/16 8.26C 7/16 11.11D 15/16 23.81E 1/4 6.35
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MULTI-POINT DRESSERS
Small elongated whole diamonds are carefullyselected for quality and uniformity of shape.
SINGLE-LAYER DRESSING BLOCKDesigned to dress straight wheels on tool roomsurface grinders. Quickly removes all previousforms or shapes.
CLUSTER TYPE DRESSER
OFF-HAND DRESSER
INDEXABLE DISC TYPE DRESSER
Designed for straight pass grinding, thesetools are of a robust construction and availablein diameters from 1/4” (6.35mm) to 3/4” (19.05mm)as standard. Finest natural diamond grits areused for rapid stock removal and fine finishapplications.
For hand trueing and dressing of abrasivegrinding wheels.
ShankDimensions
RecommendedStyle A B Use
Inch mm Inch mm
1 1/2 12.70 5/32 3.81
1 1/2 12.70 5/32 3.81
3 11/16 17.46 3/16 4.75
A
B
Small surfacegrinders maxi-mum 10" (250mm)wheels
O.D., centerless,surface grindersmaximum 20"(500mm) wheels
O.D., centerless,surface grindersover 20" (500mm)wheels
ShankDimensions
RecommendedStyle A B Use
Inch mm Inch mm
1 5/8 15.87 5/32 3.81
1 5/8 15.87 5/32 3.81
3 7/8 22.22 3/16 4.75
A
B
Small surfacegrinders maxi-mum 10" (250mm)wheels
O.D., centerless,surface grindersmaximum 20"(500mm) wheels
O.D., centerless,surface grindersover 20" (500mm)wheels
11
CHISEL & CONE PROFILE TOOLS
POLISHED CHISEL DRESSING TOOLThe finest quality flat elongated diamonds are used in our chisel edgedressing tools. They are lapped to .005" (.127mm) chisel width within.003" (.076mm) of center.
CONE LAPPED DRESSING TOOLFine quality elongated diamonds are used in our cone shaped dressingtools. They are lapped to .003" (.076mm) T.I.R.
D
40°60°75°
L
R
60°75°90°
D
L
R
DIAFORM STYLEDiaform and Pantocrush style dressers are made with the finest qualitytriangular shaped diamonds.
The grain is oriented to expose the hardest direction of the diamond tothe abrasive forces of the grinding wheel. This yields longer tool life.
Polycrystalline diamond (PCD) tool blanks can be used on very selectiveapplications.
TOLERANCES:Radius: +.0000" - .0003"
(+.0000mm - .0076mm)Trueness of Radius: +.0000" - .0001"
(+.0000mm - .0025mm)Ends Lapped: YesTool Length: +.005" - .005"
(+.127mm - .127mm)Diamond Center Set: +.003" - .003"
(+.076mm - .076mm)Diamond Size: For Heavy Duty
D A
110°
L R
L
D60°75°90°
PHONO POINTS
Specify “D” diameter, “L” length, “R” radius Specify “D” diameter, “L” length, “R” radius
For dressing small radii fine grit wheels
PROFILE TOOLS
RadiusInch mm.005 .127.010 .253.015 .381.020 .508
DimensionsInch mm
D .125 3.2L 1 25.4
RadiusInch mm.005 .127.010 .253.015 .381.020 .508
D L A RInch mm Inch mm Inch mm
Roughing 3/8 9.52 1 3/4 44.45 60° .020 – .5 – .030 .75
3/8 9.52 1 3/4 44.45 60° .002 .0513/8 9.52 1 3/4 44.45 60° .005 .1273/8 9.52 1 3/4 44.45 60° .010 .2543/8 9.52 1 3/4 44.45 60° .015 .3813/8 9.52 1 3/4 44.45 60° .020 .508Finishing 3/8 9.52 1 3/4 44.45 40° .002 .0513/8 9.52 1 3/4 44.45 40° .005 .1273/8 9.52 1 3/4 44.45 40° .010 .2543/8 9.52 1 3/4 44.45 40° .015 .3813/8 9.52 1 3/4 44.45 40° .020 .508
D L A RInch mm Inch mm Inch mm
Roughing 3/8 9.52 2 1/4 57.15 60° .020 – .5 – .030 .75
3/8 9.52 2 1/4 57.15 60° .002 .0513/8 9.52 2 1/4 57.15 60° .005 .1273/8 9.52 2 1/4 57.15 60° .010 .2543/8 9.52 2 1/4 57.15 60° .015 .3813/8 9.52 2 1/4 57.15 60° .020 .508Finishing 3/8 9.52 2 1/4 57.15 40° .002 .0513/8 9.52 2 1/4 57.15 40° .005 .1273/8 9.52 2 1/4 57.15 40° .010 .2543/8 9.52 2 1/4 57.15 40° .015 .3813/8 9.52 2 1/4 57.15 40° .020 .5083/8 9.52 2 1/4 57.15 30° .005 .127
D L A RInch mm Inch mm Inch mm
Roughing 3/8 9.52 1 3/8 34.92 60° .020 – .5 – .030 .75
3/8 9.52 1 3/8 34.92 60° .002 .0513/8 9.52 1 3/8 34.92 60° .005 .1273/8 9.52 1 3/8 34.92 60° .010 .2543/8 9.52 1 3/8 34.92 60° .015 .3813/8 9.52 1 3/8 34.92 60° .020 .508Finishing 3/8 9.52 1 3/8 34.92 40° .002 .0513/8 9.52 1 3/8 34.92 40° .005 .1273/8 9.52 1 3/8 34.92 40° .010 .2543/8 9.52 1 3/8 34.92 40° .015 .3813/8 9.52 1 3/8 34.92 40° .020 .5083/8 9.52 1 3/8 34.92 30° .005 .127
12
POLYCRYSTALLINE DIAMOND (PCD) FORM DRESSERS
Our Polycrystalline diamond dressers are ideal for Voumard & StuderCNC Profile Grinders. The carbide post allows for secure mounting.Random diamond grain orientation on the dresser’s points provideconsistent results.
RANGE: Custom designed to meet customer’s grinding profile requirements
DIMENSIONS: .05” - 4” (1mm - 100mm) wideAPPLICATION: • Highly accurate form dressing applications.
• Alternative to roll dressing.• Alternative to profile dressing.
PLEASE STATE • Wheel type.WHEN ORDERING: • Wheel size (diameter & width).
• Grit size and type.• A tool or component drawing will also be required.
A
B
PCD DRESSING TOOLS FOR CNC PROFILE GRINDERS
• A cost effective alternative to roll dressing and Diaform style dressing.• Can impart complex and highly accurate forms to grinding wheels.• Long lasting.• Less machine downtime.
FACESIDE
PCD
Item Stock No.Centrifugal Braking - For general purpose use C4710001Air Driven - For large and very small diameter wheels C4720001Replacement Wheels 60 SIC (5 pack) C4730001
ROTATRIM DEVICES FORDRESSING AND TRUEING
For a fast, easy and cost effective way to restore, dress and trueDiamond and CBN wheels.
PCD FORM DRESSERS
Inch mmA .217 5.51B .125 3.20
13
POLYCRYSTALLINE DIAMOND (PCD) CUTTING TOOLS
PCD tools are as abrasion resistant as natural diamond tools and aremuch tougher. The diamond layer consists of diamond particles that arerandomly oriented and do not have any cleavage planes or soft weardirections.
PCD tools are recommended to machine non-ferrous and very abrasivematerials. They have the capacity to out produce carbide tools 10 to100 times.
We manufacture PCD tooling for all turning, boring, drilling and millingapplications.
Cutting tools and inserts of any make can be tipped with PCD sections.There are two options:
• We can supply the tool complete.• We can tip our customers’ new tools or inserts.
RANGE OF PRODUCT LINE:PCD sections are available in three grades:1. Fine: For finishes less than 15 Micro inches (.4 micrometers).2. Medium: For standard finishes.3. Coarse: For very abrasive materials.
METALLIC:AluminumBabbittBrass, Bronze & CopperHigh Cobalt Sintered CarbideMagnesiumPre-sintered CarbideZinc Alloys
NON-METALLIC:CarbonCarbon Fiber CompositesChip BoardPre-sintered CeramicGraphiteHard RubberWood Products
PLASTICS:AcrylicFiberglass EpoxyNylon CompositesPhenolicsPoly CarbonateP.V.C. CompositesTeflon® Composites
Nose Radius Clearance Back Rake Speed Depth of Cut Feed RateWorkpiece (inch) Angle Angle (SFPM) (inch) (inch/rev)
(mm) (degrees) (degrees) (M/min) (mm) (mm/rev)
Aluminum 0.006” – 0.040” 5 – 10 + 0 – 10 3000 - 5000 0.005” – 0.020” 0.002” – 0.008”alloys 0.15 – 1.0mm 914 - 1524 0.13 – 0.51mm 0.051 – 0.20mmCopper alloys 0.010” – 0.040” 5 – 30 + 10 – 20 1500 - 3500 0.005” – 0.020” 0.001” – 0.006”including bronze 0.25 – 1.0mm 457 - 1067 0.13 – 0.51mm 0.025 – 0.15mmSintered cemented 0.040” – 0.125” 5 – 12 0 500 - 1500 0.0005” – 0.005” 0.001” – 0.003”tungsten carbide 1.0 – 3.2mm 152 - 457 0.013 – 0.13mm 0.025 – 0.076mmGlass fiber/plastic 0.030” – 0.090” 5 – 20 + 0 – 6 400 - 3600 0.001” – 0.003” 0.001” – 0.010”composites 0.76 – 2.3mm 122 - 1097 0.025 – 0.076mm 0.025 – 0.25mmCarbon/plastic 0.020” – 0.040” 5 – 20 + 0 – 6 500 - 2000 0.010” – 0.100” 0.005” – 0.015”composites 0.51 – 1.0mm 152 - 610 0.25 – 2.54mm 0.13 – 0.38mmHigh-alumina 0.010” – 0.40” 5 – 20 + 0 – 6 1500 - 3000 0.0005” – 0.005” 0.001” – 0.004”ceramics 0.25 – 1.0mm 457 - 914 0.013 – 0.13mm 0.025 – 0.10mm
STARTING PARAMETERS FOR PCD TOOLS
PCD CUTTING TOOLSRECOMMENDED USE:
PCD tools offer superior wear resistance. They are recommended onthe following materials:
FOR ROUGH AND FINISH MACHIN-ING OF NON-FERROUS AND NON-METALLIC PARTSWe offer four advanced PCD tippedinserts: 60 degree Triangle, 80 degreeRhomboid, 35 degree Rhomboid and 55
degree Rhomboid. The inserts are single-sided with a tolerance classof “M” or better. • Longer PCD edge lengths allow larger depths of cut, reducing the
14
POLYCRYSTALLINE DIAMOND (PCD) CUTTING TOOLS
IN-STOCK, HIGH PERFORMANCE PCD TIPPED INSERTS
SAMPLES OF OUR CUSTOM-DESIGNED TOOLS
PCD MicroboreAdjustable Cartridge
Piston Turning Tool
Milling CartridgePCD Form Tools
PCD Commutator Tool PCD Boring Tool PCD Boring Tool
• We offer brazed tipped cutting tools, boring tools and cut off tools. • Tools are custom designed by our design engineers, working from a customer supplied drawing.• Custom tools are quoted on request.
PCD Router PCD Router
number of passes - resulting in shorter cycle time and increasedproductivity.
• Large PCD sections provide more holding power - resulting in more re-lapsand fewer tip pull offs.
• Polished PCD tops for keener edges and better chip flow. • Can be used to machine aluminum in both neutral and negative holders.• Edges ground on CNC equipment for consistency and quality finishes. • All inserts are manufactured to the latest ISO standard for assured quality.
Description StyleStock No.
DimensionsANSI ISO I.C. T R D
11o Relief angle, TPGN 321 TPGN 160304 S44400043
3/8” 1/8” 1/64”N.A.1 corner tipped, no hole 9.52mm 3.18mm 0.4mm
11o Relief angle, CPMW 32.52 CPMW 09T308 S44400044 3/8” 5/32” 1/32” 11/64”1 corner tipped, screw hole 9.52mm 4.0mm 0.8mm 4.32mm
11o Relief angle, CPMW 432 CPMW 120408 S44400097 1/2” 3/16” 1/32” 7/32”1 corner tipped, screw hole 12.7mm 4.76mm 0.8mm 5.5mm
0o Relief angle, 10o top rake, DNMA 432 DNMA 150408 S44400045 1/2” 3/16” 1/32” 13/64”1 corner tipped, pin lock hole 12.7mm 4.76mm 0.8mm 5.2mm
7o Relief angle,DCMT 4, 2.5,1 DCMT 11T304 S44400098
3/8” 5/32” 1/64” 11/64”1 corner tipped, screw hole 9.52mm 3.96mm 0.4mm 4.4mm
0o Relief angle, 10o top rake, VNMA 331 VNMA 160404 S44400046 3/8” 3/16” 1/64” 5/32”1 corner tipped, pin lock hole 9.52mm 4.76mm 0.4mm 3.8mm
5o Relief angle,VBMW 331 VBMW 160404 S44400099 3/8” 3/16” 1/64” 11/64”
1 corner tipped, screw hole 9.52mm 4.76mm 0.4mm 4.4mm
We will custom engineer other sizes and styles to meet your application needs in quantities of 10.
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STANDARD PCD TIPPED INSERTS - usually available to ship the same day the order is received.
15
POLYCRYSTALLINE DIAMOND (PCD) DRILLS & WEAR PARTS
EVERLAST ® PCD DRILL
ADVANTAGES:• Vastly improved drill life (the drill is not a fabrication).• Improved drill hole surface finish.• Greater tolerance control.• Greatly reduced downtime due to fewer drill changeovers and
quality checks.• Rugged construction enables the Everlast® drill to handle diffi-
cult conditions that damage other drills beyond use.• Faster drill speeds and feeds.• Designed for very high silica aluminum.• Designed for many current composite and aerospace materials
such as Kevlar® and CFC.
PCD WEAR PARTSThe life of PCD components is typically 100 times that of the carbideor HSS predecessor. The low friction coefficiency of PCD, togetherwith its ultra hardness, ensures that high levels of component accura-cy are maintained over the component’s life span.ADVANTAGES:• Reduced whole life costs.• Reduced downtime.• Reduced changeover rates.• Increased component accuracy.PCD WEAR SURFACES ARE USED FOR:• Vee Supports.• Backing Plates.• Gauging Fingers.• Gauging Points.• Back Stops.• Face Grinding.• PCD Rings.
INNOVATION DELIVERS A UNIQUE PCD DRILLWe have successfully developed the solution to the manufacturing andengineering industry’s need to apply PCD (polycrystalline diamond)technology to today’s machining challenges.
The benefits of machining non-ferrous materials with PCD are wellestablished. Applying PCD technology to the drilling process has longbeen an objective for many companies.
While electroplated, CVD coated or fabricated drills have failed tomeet the expectations and technical challenges of modern machining,the Everlast® drill meets and exceeds those expectations.
Existing products exhibit short life, failing fabrication joints, and a lackof a rugged cutting edge. Our patented design of a PCD section, fullyintegrated into the carbide drill, has overcome these problems.
SPECIFICATIONS:• Available in 9/64” (3.8mm) - 1/2” (13mm) diameters.• Standard lengths up to 8” (200mm), others by application.• Helical flute.• Straight flute.• Made to customer’s specification.
U.S. Pat. No. 5,580,196 European Patent: EP0560951
16
POLYCRYSTALLINE DIAMOND (PCD) COMBINATION TOOLING
Designed to meet each customer’s specific application.For machining non-ferrous materials, including high silica aluminumand other exotic materials.
• Combines several tool operations in one pass.• Diamond cutting edge = high precision.• Long life = reduced downtime.• Reduced number of machining stations.• Reduced tooling stock holding.• Tamperproof tooling.• High component consistency.
CASE STUDIESTOOL FUNCTION: Drill and FormPRODUCT BEING MACHINED: High pressure aluminum housingSURFACE SPEED: 2,100 ft/min (650m/min)STOCK REMOVAL: .236”- .315” (6-8mm) on top recess faceFEED RATE: 120 IPM (3000mm/min)SURFACE FINISH ACHIEVED: 0.7RaFITTING STANDARD: ISO40NUMBER OF FORMING OPERATIONS: 7BENEFITS:
• Increase production capacity by 60-70% due to the ability toperform 2 functions in one pass.
• Reduced machine downtime.• Reduced machine changeover time.
TOOL FUNCTION: Size and Form PRODUCT BEING MACHINED: High pressure aluminum housingSURFACE SPEED: 1,500 ft/min (450m/min)STOCK REMOVAL: .02” (0.5mm)FEED RATE: 6 IPM (150mm/min)SURFACE FINISH ACHIEVED: 0.4RaFITTING STANDARD: MK3NUMBER OF FORMING OPERATIONS: 15BENEFITS:
• Ability to achieve a very high level of surface finish which elim-inates the burnishing operation.
• Reduced machine downtime.• Reduced machine changeover time.
TOOL FUNCTION: ReamingPRODUCT BEING MACHINED: Spark plug portsSURFACE SPEED: 160 ft/min (50m/min)STOCK REMOVAL: .024” (0.6mm)FEED RATE: .008”/Revolution (0.2mm/Revolution)SURFACE FINISH ACHIEVED: 0.2RaFITTING STANDARD: Steiber ChuckNUMBER OF FORMING OPERATIONS: 8BENEFITS:
• Number of pieces being machined now with above tool: 250,000.• Number of pieces being machined with previously used carbide
tools: 15,000.• Reduced machine downtime.• Reduced machine changeover time.
Machining high silica aluminum diecasting
Machining high pressure aluminum cylinders
Brass cylinder reamer
Twin diameter and chamfer tool -18% silica aluminum diecasting
Spark plug port reamer
Diameter and face forming tool -aluminum diecasting
Multiple diameter and face formingtool - aluminum diecasting
Drill form and chamfering tool -aluminum component
PCD COMBINATION TOOLING
17
POLYCRYSTALLINE CBN (PCBN) CUTTING TOOLS
Grade Description Features Materials Application
CLA Low PCBN Long Tool Life Hardened Steels, Gray Cast Irons Light Continuous CutsContent Die Steels, Bearing Steels
CLB Low PCBN Long Tool Life Alloy Steels, Die Steels Continuous Cuts to LightContent Hardened Steels Interrupted Cuts
Low PCBN Good Balance Between Tool Life Hardened Steels, CL Content and Shock Resistance Cast Irons, Powdered Metals, Moderate Interrupted Cuts
Tool Steels
High PCBN Excellent Wear and Fracture Ni-Hard, High Chrome Alloys, Severe Interrupted Cuts,CHA Content Resistance in Severe Interrupted Cuts Cast Irons, Sintered Irons, Heavy Stock RemovalPowdered Iron Alloys
High PCBN Excellent Wear and Fracture Ni-Hard, Chilled Severe Interrupted Cuts,CHB Content Resistance in Severe Interrupted Cuts Irons, Gray Cast Irons, Heavy Stock RemovalHard Facing Materials
High PCBN Excellent Toughness and Abrasion Gray Cast Irons, Severe Interrupted Cuts,CHC Content Resistance Super Alloys, Nickel Alloys, Heavy Stock RemovalSintered Ferrous Metals
High PCBN Excellent Toughness and Abrasion Gray Cast Irons, ModerateCH Content Resistance Super Alloys, Nickel Alloys Interrupted CutsSintered Ferrous Metals
Abrasive Technology features PCBN tools for all turning, boring andmilling applications. We offer two groups:• BRAZED TIPPED PCBN tools and inserts.• SOLID inserts with PCBN in a ceramic binder throughout the insert,
or a full face 1/32” (.787mm) thick layer on a carbide substrate.
PHYSICAL PROPERTIESThe hardness of PCBN falls between diamond and carbide. It is con-siderably more abrasion resistant than both carbide and ceramic cut-ting tools. PCBN combines a high degree of toughness and hot hard-ness. These properties make it particularly suited to machine hard-ened steels, cast irons and super alloys.
GRADESCBN is available in several grades, each having specific propertiesand usage. There are two basic categories:
MACHINING PARAMETERS FOR CBN TURNING/BORING TOOLS
PCBN CUTTING TOOLS
STEEL GRADE COMPARISON CHART - Polycrystalline Cubic Boron Nitride (PCBN)
• Low content CBN grain primarily designed for finishing cuts on hardenedsteel.
• High content CBN grain designed for machining cast iron, hard facingmaterial and Nickel alloys.
INSERT DESIGNATIONSOur Polycrystalline inserts use the ANSI/ISO standard to identify indexableinserts. We also offer brazed tipped “shank”cutting tools, boring tools and cut-offtools. These are usually specified by print.
Material Hardness HRC Stock Removal Feed Finishing Cuts -1.0mm Feed ft/min m/min in/rev mm/rev ft/min m/min in/rev mm/rev
Cold Work Tool Steels 60 197–394 60–120 .002–.01 0.05–0.25 3,937–5,906 100–150 .002–.008 0.05–0.2High Speed Steels 62 197–394 60–120 .002–.01 0.05–0.25 3,150–4,724 80–120 .002–.008 0.05–0.2Ni Hard White Irons 55–68 131–262 40–80 .002–.008 0.05–0.20 – – – –Gray Cast Irons 220HR 1,640–2,625 500–800 .004–.012 0.1–0.3 – – – –Bearing Steels 58–60 – – – – 3,937–5,906 100–150 .002–.008 0.05–0.2Hard Facing Cobalt Alloys – 656–820 200–250 .008 0.2 – – – –Hard Facing Nickel Alloys – 394–492 120–150 .008 0.2 – – – –Surface Hardened Parts 55–58 – – – – 3,150–4,724 80–120 .002–.008 0.05–0.2
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PCBN / NATURAL DIAMOND CUTTING TOOLS
PCBN InsertSolid PCBN Insert Full Face Insert PCBN Boring Tool
C
D
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Natural Diamond Turning Tool
PHYSICAL PROPERTIESNatural diamond is the hardest of all cutting tool materials. The crystalstructure is extremely dense and lends itself to be relapped to a verysharp edge. At the same time, it is very brittle and therefore is sensitiveto machine vibration and interrupted cuts.
Because it has the lowest coefficient of expansion of all cutting toolmaterials, it is dimensionally very stable. This makes it possible toachieve very close tolerances, even in long production runs.
NATURAL DIAMOND CUTTING & BURNISHING TOOLS
STANDARD PCBN TOOL EXAMPLES
Metallic Non-MetallicMaterials Materials
SpeedSFPM 600 - 10,000 500 - 4,500m/min 183 - 3,048 152 - 1,372
Feedin/rev .001 - .006 .001 - .020
mm/rev .025 - .152 .025 - .508
Depth of Cutin .0005 - .060 .0005 - .060
mm .0127 - 1.524 .0127 - 1.524
Valve Seat Tools
SHAPED SPECIALTIES
BURNISHING TOOLFor Elliot Wiedeke Fixtures
GAGE POINTFor Crane Lapmaster andSpeedfam Lapping Machines
APPLICATIONS
Natural diamond tools are ideallysuited to achieve reflective finish-es on metallic surfaces, transpar-ent finishes on plastics and lessthan 8 micro-inch on other com-patible materials:• Contact lenses.• Interocular lenses.• Copy machine drums.
MATERIALS
Light metals: AluminumMagnesium
Soft metals: CopperBrass Nickel
Plastics: TeflonNylon Acrylic
OPERATING PARAMETERS
Contact Lens
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SERVICES
Special tools are designed andquoted on request. Please referto the drawings in this catalogas an aid in communicatingyour request for quote. Also,
the following information is required to best determine your needs:
1. Part drawing indicating the position of the tool and the direction oftool travel.
2. Type of equipment and maximum feeds and speeds available.
3. Maximum depth of cut. The size of the Polycrystalline diamond sec-tion will influence the price of the product. It is therefore importantthat the maximum depth of cut be specified when a tool is ordered.
CELCEL
PCD/PCBN TIPPED CUTTING TOOLS - TOOL SERVICE
NATURAL DRESSING TOOLS
We offer three types of service:CLASS 1 - RELAPThe tools are contour ground.However the IC/Tool geometryis reduced. If it is essential thatthe tool geometry remainsunchanged, a class 2-3 servicecan be done.
CLASS 2 - SHIM AND RELAPStrips of resizing material areadded to the back edges of thePCD/PCBN insert, and then con-tour ground to the original toolgeometry.
SINGLE POINT DRESSERSWe can reset all our resettable diamonds into a completely new shank.
POLISHED DIAMOND TOOLSBoth Chisel tools and Cone tools can be relapped and regenerated.
IC IC
Resizing material
New material
.004 in.(0.1mm)
20º
PRODUCT DESIGN ENGINEERING SERVICESThis determines the CEL (cutting edge length) desired for maximumeffectiveness.
4. Material to be machined and Rockwell hardness (if ferrous metalsare involved).
5. The objective of this design:• Increase in tool life.• Better surface finish.• Minimize chipping.
6. Drawing or description of tools presently used or insert designation.
7. Identify the carbide fabricator for special inserts.
CLASS 3 - RETIPThe PCD/PCBN material is re-placed and reground to the orig-inal tool geometry.
EDGE PREPARATION‘T’/’K’ Lands or honed edgescan be applied to PCBN tools asrequired.
Everlast® is a registered trademark of Abrasive Technology. Kevlar® and Teflon® are registered trademarks of DuPont.©Copyright 2003 Abrasive Technology Printed 6/03
Custom-Engineered ToolingWe welcome the opportunity to quote on any special grind-ing tools you may need. Please send complete part draw-ings and tool specifications when requesting a quote. Callany of the numbers listed below for more information.
Additional ProductsWe manufacture electroplated, brazed, metal, resin, and vit-rified bonded grinding wheels using diamond and CBN. Wealso manufacture single-point diamond and PCD/PCBNtools.
Markets ServedWe serve the aerospace, automotive, bearing, ceramic,composite, electronics, glass, lapidary, medical, oil & gas,ophthalmic, stone, textile, tires, tool & die and toolroommarkets with thousands of custom-engineered and in-stockproducts.
10 locations for your diamond tool needs around the world.
abrasive technologyWORLD HEADQUARTERS EUROPEAN HEADQUARTERS ASIAN HEADQUARTERSAbrasive Technology, Inc. Abrasive Technology Ltd. Abrasive Technology Asia Pacific Pte. Ltd.8400 Green Meadows Dr. Roxby Place • Fulham, London Blk 1093 Lower Delta Rd. 05-11/13P.O. Box 545 SW6 1RT United Kingdom Tiong Bahru Industrial EstateLewis Center, Ohio 43035 USA Ph: 44.20.7471.0200 Singapore 169204Ph: 1.740.548.4100 Fax: 44.20.7471.0202 Ph: 65.6270.6878Fax: 1.740.548.7617 Fax: 65.6270.6877
www.abrasive-tech.com
®10 LOCATIONS WORLDWIDE
