A TRADITION OF QUALITY SINCE 1966 DIAMOND AND CBN WHEELS

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Philomena Gardner
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1 A TRADITION OF QUALITY SINCE 1966 DIAMOND AND CBN WHEELS

2 POLTAVA DIAMOND TOOLS has been manufacturing top-quality diamond tools for the machine building, glass, electronic and woodworking industries since It is committed to constantly improving production quality and has been certified in accordance with ISO 9001:2008. We offer three product lines to meet the quality demands and price requirements of our customers: PREMIUM our newest line of diamond and CBN wheels specially designed to compete with top international brands for use on CNC machines but at a substantially lower price used in machine building, woodworking and metallurgy for the production and sharpening of circular and band saws, metal cutting and specialty tools, as well as machine building parts STANDARD high quality resin and metal bonded diamond and CBN wheels for a wide range of industrial applications BASIS resin bonded diamond wheels for when price is a higher priority than tool life Our specialists have a wealth of experience in the production and use of diamond wheels and tools, and POLTAVA DIAMOND TOOLS is always pleased to offer you our technical support and assistance in choosing diamond wheels and tools. WE LOOK FORWARD TO WORKING WITH YOU!

3 General information 12A2-45 4B2 Cup grinding wheels Grinding machine types and wheels used 12 11V9-70 Cup grinding wheels 20 6A2 Flat recessed grinding wheels 25 1А1 Straight grinding wheels 16 12V5-45 Cup grinding wheels 21 12M2-45 Grinding wheels 25 14А1 Straight grinding wheels 17 12V9-45 Cup grinding wheels 21 4A2 Dish grinding wheels 26 1А1R Cut-off wheels 17 12V9-20 Dish grinding wheels 22 12A V1 Grinding wheels (special) 18 12V А9 Recessed flat grinding wheels 27 14EE1 Flat grinding wheels with double-sided conical profile 18 4V V5-20 Dish grinding wheels 27 1FF1 Flat grinding wheels with semicircular convex profile 19 4BT9 23 Wheels in our STANDARD product line 28 14FF1 Grinding wheels with semicircular convex profile 19 12R4 24 QUESTIONNAIRE for selecting PREMIUM wheels made by PJSC POLTAVA DIAMOND TOOLS 29

4 12V9-20, 12V9-25, 4V2, 12R4, 12A2-20, 4BT9 1A1 12A2-20, 4А2, 12V9-45, 12M2-45, 6A2 4

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6 International Size Standards and their applications by operation U.S. Standard ANSI В mesh D426 D301 D251 D213 D / / / / /150 40/45 50/60 60/70 70/80 100/ / / / / /125 D126 D / /90 120/ / / /80 Resin Resin (coated diamond) Resin (non-coated diamond) Metal (high productivity) D213 D107 0,63 0,16 1,0 0,32 1,0 0,32 D91 D46 0,32 0,16 0,63 0,20 0,63 0,20 D126 D46 0,32 0,10 0,63 0,16 0,80 0,20 D126 M16 0,32 0,05 0,50 0,10 0,63 0,125 D213 D126 1,0 0,32 1,25 0,63 1,25 0,63 D107 D91 0,50 0,16 1,0 0,32 1,25 0,40 D64 D46 0,32 0,16 0,63 0,16 0,63 0,32 6

CONCENTRATION OF DIAMOND GRAIN IN THE DIAMOND LAYER The concentration of diamond grain is the content by weight of diamond in the diamond layer.

The diamond concentration is one of the most important characteristics of a diamond tool, determining its cutting ability, productivity, length of usage and cost.

7 CONCENTRATION OF DIAMOND GRAIN IN THE DIAMOND LAYER The concentration of diamond grain is the content by weight of diamond in the diamond layer. The unit of weight for diamond grain is a carat (ct), 1ct=0.2 g. The diamond concentration is one of the most important characteristics of a diamond tool, determining its cutting ability, productivity, length of usage and cost. The choice of concentration depends on the type of tool, the form and size of the working surface, the diamond grit size, the wear-resistance of the bond, and the conditions in which the tool will be used. The following are guidelines for the choice of diamond concentration in the diamond layer: for a small contact surface between the grinding wheel and the workpiece, for example as in circular grinding, a high diamond concentration should be chosen. This provides higher wear resistance for the wheel, even at high loads: a large contact surface necessitates lowering the grinding temperature and the grinding intensity. In this case a lower diamond concentration should be used. Wheels are produced with diamond concentrations of 25%, 50%, 75%, 100% and 150% (It is possible to produce wheels with other concentrations if needed by the customer). Низкая концентрация алмазного порошка Высокая концентрация алмазного порошка Grinding with coolant is to be preferred, since the grinding wheel is subject to less wear and can be used under more demanding conditions, thus increasing grinding productivity. In addition, the probability of thermal damage to the workpiece (the appearance of burn marks) is reduced. Liquid coolants are recommended as coolants for diamond grinding wheels. 7

8 SHAPES OF DIAMOND GRINDING WHEELS Diamond grinding wheels described in the catalog are based on the FEPA standard for diamond tools Identification number for shapes of grinding wheels cores 8

1) Peripheral velocity of the wheel during grinding Resin bond Grinding type Diamond CBN Dry Wet Dry Wet Face 20-30 m/sec 30-40 m/sec Circular internal 8-12 m/sec 10-20 m/sec Circular external 20-30

9 1) Peripheral velocity of the wheel during grinding Resin bond Grinding type Diamond CBN Dry Wet Dry Wet Face m/sec m/sec Circular internal 8-12 m/sec m/sec Circular external m/sec Sharpening m/sec m/sec m/sec m/sec m/sec m/sec m/sec Metal bond Grinding type Diamond CBN Dry Wet Dry Wet Face m/sec m/sec Circular internal 8-12 m/sec m/sec Circular external m/sec Sharpening 8-12 m/sec m/sec m/sec m/sec m/sec m/sec m/sec 9

10 When using diamond grinding wheels, the following instructions should be observed: grinding wheels are to be mounted on holders or flanges and should not be removed until final usage has occurred; the tools are to be mounted securely on the machine spindle in accordance with the technical specifications of the equipment used for diamond tool machining; the cleaning of resin bonded diamond wheels is to be performed with a pumice stone, of metal bonded wheels with a green silicon carbide bar made with grit sizes 1 or 2 sizes larger that of the diamond wheel. Dressing (truing) of the diamond layer is necessary to restore its shape, eliminate defects from its working surface, and to restore the required profile. As a rule this is performed without coolant. The most productive way of dressing a diamond layer is to grind it with abrasive wheels. The dressing is performed by wheels of white alumina and green silicon carbide with vitrified bonds with grit sizes 1 or 2 sizes larger than those of the diamond wheels. Wheels with a hardness of K-H are necessary for dressing resin bond wheels and wheels of a hardness of M-K are necessary for dressing metal bond wheels. The smaller the grit size of the superabrasive material, the softer the dressing tool must be. Diamond grinding wheel position Peripheral speed, m/s Abrasive wheel Condition of dressing Diamond wheel Line feed, m/min Cross feed, mm/double stroke Diamond grinding wheel set on a machine fixture or in the center of circular grinding or sharpening machine Diamond grinding wheel set on the spindle of a grinding or sharpening machine ,5 1,0 1,0 2,0 0,02 0, ,5 1,0 0,02 0,04 Diamond layer characteristics Characteristics of profiling wheel Type of bonds Diamond grade, FEPA Standard Abrasive type Abrasive grades Hardness D181-D126 20; 16; 1 M-L Resin bonds D107-D76 D64-D46 Aluminum oxide 12; 10; 8 L-K 8; 6; 4 K-J M40-M16 М40; М28 J 10

B8-00 Cutting speed Vc=15 25 m/s Feed rate Vf = 0, 3 0,8 m/min Infeed ae = 0,3 1,0 mm B8-03 M8-01 M8-02 B9-00 B9-01 B9-02 B1000 B1002 For creepfeed grinding of tungsten carbide and steel workpieces

Recommended for narrow edged grinding wheels such as 14А1 and 14FF1. For sharpening and grinding of tungsten carbide and steel workpieces with coolants. Made with diamond and CBN micropowders.

11 B8-00 Cutting speed Vc=15 25 m/s Feed rate Vf = 0, 3 0,8 m/min Infeed ae = 0,3 1,0 mm B8-03 M8-01 M8-02 B9-00 B9-01 B9-02 B1000 B1002 For creepfeed grinding of tungsten carbide and steel workpieces on CNC machines with coolants. The bonds are characterized by excellent cutting quality, wear resistance and the highest profile retention. Recommended for narrow edged grinding wheels such as 14А1 and 14FF1. For sharpening and grinding of tungsten carbide and steel workpieces with coolants. Made with diamond and CBN micropowders. Recommended for face grinding of circular saw teeth and metal cutting tools. For sharpening and grinding of tungsten carbide and steel workpieces with coolants. Higher wear resistance than В9-00. Recommended for flank and top grinding of circular saw teeth and metal cutting tools. Cutting speed Vc=15 25 m/s Feed rate Vf = 0,05 1,0 m/min Infeed ae = 1,0 2,0 mm Cutting speed Vc=15 25 m/s Feed rate Vf = 0,05 1,0 m/min Infeed ae = 1,0 3,0 mm Cutting speed Vc=15 25 m/s Feed rate Vf = 0,05 0,1 m/min Infeed ae = 1,0 3,0 mm Cutting speed Vc=15 25 m/s Feed rate Vf = 0,1 0,25 m/min Infeed ae = 0,1 0,3 mm Cutting speed Vc = m/s Feed rate Vf = 0,1 0,25 m/min Infeed ae = 0,1 0,2 mm Cutting speed Vc = m/s Feed rate Vf = 0,1 0,25 m/min Infeed ae = 0,1 0,3 mm Cutting speed Vc = m/s Cutting speed Vc = m/s Feed rate Vf = 1 5 m/min Infeed ae = to 0,1 mm 11

12 VOLLMER CP 200 D T X U H , VOLLMER CHD V9-25 9P D T X W H (2,5+2,5) D T X U H , D T X U H , D T X U H ,5 5,5 32 VOLLMER CHD V9-25 9P D T X W H (2,5+2,5) D T X U H ,5 5,5 32 VOLLMER FX 100 D T X U H ,

13 VOLLMER CL 200 VOLLMER CX 100 9P3153 D T X W H (2,5+2,5) D W X U H , A2 3M0008 D W X T H α (2,5+2,5) 0 D T X U H , D T X U H , D T U X H D T U X H D T X W H (2,5+2,5) D W X T H

14 D T X H D T X H D T X H D T X H D T X H D U X T H D U X T H

15 D T X H D T X H D T X H D U X T H D U X T H ,75 D T X H ,75 D T X H ,75 D T X H ,75 D U X T H ,75 15

16 STRAIGHT GRINDING WHEELS Application: Used for machining of conical, cylindrical and flat surfaces, cylindrical and conical apertures; Machining of cylindrical surface parts and surface ends at one set-up; Sharpening and finishing of carbide tools. Catalog number D, mm T, mm Х, mm H, mm 16

STRAIGHT FLAT GRINDING WHEELS Application: Used for machining of conical, cylindrical and flat surfaces, cylindrical and

carbide tools. Application: Used for cutting carbide and high-speed steels.

0 10 32 6D0234 200 1.5 5 30 6Q0234 200 1.2 5 30 6M0701 300 1.

2-5-32 with diamond grit size D 251, with resin bond: 6-0206 1A1R 150-1.

17 STRAIGHT FLAT GRINDING WHEELS Application: Used for machining of conical, cylindrical and flat surfaces, cylindrical and conical apertures; Machining of cylindrical surface parts and surface ends at one set-up; Sharpening and finishing of carbide tools. Application: Used for cutting carbide and high-speed steels. Catalog number D, mm T, mm Х, mm H, mm D Q M Example of an order for a straight grinding wheel 1A1R ( catalog number ), parameters with diamond grit size D 251, with resin bond: A1R D251 В1000 PREMIUM The plant produces the above-mentioned shapes and dimensions with Cubic Boron Nitride (CBN). Example of an order for a straight CBN wheel 1A1R ( catalog number ), parameters with CBN grit size B213, with resin bond: A1R B213 В1000 PREMIUM 17

18 Application: Used for grinding of cylindrical and tapered surfaces; Grinding of chip grooves and flute grinding. FLAT GRINDING WHEELS WITH DOUBLE-SIDED CONICAL PROFILE Application: Grinding of profiled workpieces made of carbide and other hard-to-process materials. 14EE1 D*T*U*X*V*H Example of an order for a grinding wheel 14EE1 ( catalog number ), parameters with diamond grit size D 64, with resin bond: EE D64 В8-03 PREMIUM The plant produces the above-mentioned shapes and dimensions with Cubic Boron Nitride (CBN). Example of an order for a CBN wheel 14EE1 ( catalog number ), parameters with CBN grit size B64, with resin bond: EE B64 В8-03 PREMIUM 18

19 FLAT GRINDING WHEELS WITH SEMICIRCULAR- CONVEX PROFILE FLAT GRINDING WHEELS WITH SEMICIRCULAR- CONVEX PROFILE 19

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21 Application: Used for sharpening and finishing (top grinding) of cutting tools. Example of an order for a CBN wheel 12V9-45 (catalog number ), parameters , with CBN grit size B76, 21

22 Application: Used for sharpening and finishing (face grinding) of circular saw teeth and other tungsten carbide tools. Example of an order for a dish wheel 12V9-20 (catalog number ), parameters , with diamond grit size D64, with resin bond: V , D64 В9-00 PREMIUM The plant produces the above-mentioned shapes and dimensions with Cubic Boron Nitride (CBN). Example of an order for a CBN wheel 12V9-20 (catalog number ), parameters , with CBN grit size B64, with resin bond: V , B64 В9-00 PREMIUM Other specifications and sizes are available on request. 12V Application: Used for sharpening and finishing (face grinding) of circular saw teeth and other tungsten carbide tools. Catalog number D, mm Т, mm Х, mm U, mm Н, mm , ,5 5,5 32 Example of an order for a dish wheel 12V9-25 (catalog number ), parameters ,5-5,5-32 with diamond grit size D64, with resin bond: V ,5-5,5-32 D64 В9-00 PREMIUM The plant produces the above-mentioned shapes and dimensions with Cubic Boron Nitride (CBN). Example of an order for a CBN wheel 12V9-25 (catalog number ), parameters ,5-5,5-32 with CBN grit size B64, with resin bond: V ,5-5,5-32 B64 В9-00 PREMIUM Other specifications and sizes are available on request. 22

4V2 4V2 D*W*X*T*Н Catalog number D, mm W, mm Х, mm T, mm Н, mm 0-3001 100 4 2 13 25 0Q3002 125 4 2 13 32 Example of an order for a dish wheel 4V2 (catalog number 0-3001), parameters 100-4-2-13-25

Example of an order for a CBN wheel 4V2 (catalog number 0-3001), parameters 100-4-2-13-25 with CBN grit size B46, with resin bond: 0-3001 4V2 100-4-2-13-25 B46 В9-00 PREMIUM Other specifications and

Catalog number D, mm Т, mm X, mm W, mm H, mm 5-0400 75 8 1 10 20 3-3035 125 12 1 10 20 Example of an order for a dish grinding wheels 4BT9 (catalog number 3 3035), parameters 125-12-1-10-20 with

23 4V2 4V2 D*W*X*T*Н Catalog number D, mm W, mm Х, mm T, mm Н, mm Q Example of an order for a dish wheel 4V2 (catalog number ), parameters with diamond grit size D46, with resin bond: V D46 В9-00 PREMIUM The plant produces the above-mentioned shapes and dimensions with Cubic Boron Nitride (CBN). Example of an order for a CBN wheel 4V2 (catalog number ), parameters with CBN grit size B46, with resin bond: V B46 В9-00 PREMIUM Other specifications and sizes are available on request. 4BT9 DISH GRINDING WHEELS 4BT9 D T X W H Application: Used for sharpening and finishing (face grinding) of circular saw teeth and other tungsten carbide tools. Catalog number D, mm Т, mm X, mm W, mm H, mm Example of an order for a dish grinding wheels 4BT9 (catalog number ), parameters with diamond grit size D64, with resin bond: BT D64 B9-00 PREMIUM The plant produces the above- mentioned shapes and dimensions with Cubic Boron Nitride (CBN). Example of an order for a dish grinding wheels 4BT9 (catalog number ), parameters with CBN grit size B64, with resin bond: BT B64 B9-00 PREMIUM Other specifications and sizes are available on request. 23

24 Application: Used for sharpening and finishing of front surfaces of reamer teeth, cutters, circular saws, drawing dies and tools made of tungsten carbide. Example of an order for a dish wheel 12R4 (catalog number ), parameters with diamond grit size D64, with resin bond: R D64 В9-00 PREMIUM The plant produces the above-mentioned shapes and dimensions with Cubic Boron Nitride (CBN). Example of an order for a CBN wheel 12R4 (catalog number ), parameters , with CBN grit size B64, with resin bond: R B64 В9-00 PREMIUM 4B2 DISH GRINDING WHEELS Application: Used for sharpening and finishing (face grinding) of circular saw teeth and other tungsten carbide tools. Catalog number D, mm Т, mm Х, mm W, mm Н, mm ,5 6 31, , ,5 6 31, , Example of an order for a dish wheel 4B2 (catalog number ), parameters with diamond grit size D64, with resin bond: B D64 В9-00 PREMIUM The plant produces the above-mentioned shapes and dimensions with Cubic Boron Nitride (CBN). Example of an order for a CBN wheel 4B2 (catalog number ), parameters , with CBN grit size B64, with resin bond: B B64 В9-00 PREMIUM Other specifications and sizes are available on request. 24

4 Example of an order for a grinding wheels 6A2 (catalog number 3-0088), parameters 125-5(2,5+2,5)-10-24-32 with diamond grit size D46/D126, with resin bond: 3-0088 6A2 125-5(2,5+2,5)-10-24-32

25 6A2 FLAT RECESSED GRINDING WHEELS α 0 Used for sharpening and finishing (top grinding) of circular saw teeth and other tungsten carbide tools. Sharpening of circular saw Catalog number D, mm W, mm X, mm T, mm H, mm 3K (2,5+2,5) (2,5+2,5) M (2,5+2,5) J (2,5+2,5) Example of an order for a grinding wheels 6A2 (catalog number ), parameters 125-5(2,5+2,5) with diamond grit size D46/D126, with resin bond: A (2,5+2,5) D46/D126 B9-00 PREMIUM The plant produces the above- mentioned shapes and dimensions with Cubic Boron Nitride (CBN). Example of an order for a grinding wheels 6A2 (catalog number ), parameters 125-5(2,5+2,5) with CBN grit size B46/B126, with resin bond: A (2,5+2,5) B46/B126 B9-00 PREMIUM 0 α Other specifications and sizes are available on request. 9P3153, 9A3153 α 9M M2-45 GRINDING WHEELS 12M2-45 D T X W H Used for sharpening and finishing (top grinding) of circular saw teeth and other tungsten carbide tools. Sharpening of circular saw Catalog number D, mm Т, mm X, mm W, mm H, mm 9P (2,5+2,5) A (2,5+2,5) M (2,5+2,5) 32 Example of an order for a grinding wheels 12M2-45 (catalog number 9P3153), parameters (2,5+2,5)-32 with diamond grit size D46/D126, with resin bond: 9P M (2,5+2,5)-32 D46/D126 B9-00 PREMIUM The plant produces the above- mentioned shapes and dimensions with Cubic Boron Nitride (CBN). Example of an order for a grinding wheels 12M2-45 (catalog number 9P3153), parameters (2,5+2,5) -32 with CBN grit size B46/B126, with resin bond: 9P M (2,5+2,5)-32 B46/B126 B9-00 PREMIUM Other specifications and sizes are available on request. 0 α 25

26 Application: Used for sharpening and finishing (face grinding) of multiple-blade tools. Application: Used for sharpening and finishing of front surfaces of reamer teeth, cutters, circular saws, drawing dies and tools made of tungsten carbide. Example of an order for a dish wheel 12A2-20 (catalog number ), parameters with diamond grit size D64, with resin bond: А D64 В9-00 PREMIUM The plant produces the above-mentioned shapes and dimensions with Cubic Boron Nitride (CBN). Example of an order for a CBN wheel 12A2-20 (catalog number ), parameters , with CBN grit size B64, with resin bond: A B64 В9-00 PREMIUM 26

27 Application: Used for sharpening and finishing of multiple-blade tools cutter back surfaces (with straight and spiral teeth), drills and other tools made of tungsten carbide. 27

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32 PJSC POLTAVA DIAMOND TOOLS

MANUFACTURING TECHNOLOGY

MANUFACTURING TECHNOLOGY UNIT IV SURFACE FINISHING PROCESS Grinding Grinding is the most common form of abrasive machining. It is a material cutting process which engages an abrasive tool whose cutting