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SAK ABRASIVES LIMITED

TOPLINE

Started in 1997 with the objective of supplying Indian Industries with the high performancegrinding wheels at affordable prices. At that time growing Indian market was supplied byvery few companies and the trend towards precision engineered products left a void thatwe were quick to fill. In collaboration with the Swiss company Rastawerk Switzerland A.G,we started our range with basic resin bonded DC and cut off wheels made out ofplant in Chennai, India.

Since then there has been no looking back as we expanded our product line in responseto the evolving need of our customers. Backed by philosophy of rapid but sustainablechange we developed full range of resin & vitrified bonded abrasives, coated abrasivesand the latest addition of Super Abrasives. This has been accompanied by continualinvestment in the up gradation and modernization of our plant, paving the road to the future.

Whether you are regrinding or making new tools, we have the diamond or CBN grindingwheel for you. With the help of our technical partner M/s. Superabrasives INC, USA,we have worked with many of the OEM's and understand the demands of the machineryand what is required of the grinding wheels. Carbide, Stainless or High speed steelend mills, drills, punches, reamers, hole saws and the like all require multiple steps inmanufacturing and we have developed bond systems and have qualified exactspecifications for each operation. With the latest technology, we are offering all types ofDiamond / CBN wheels to FEPA standard on the CNC machines such as Walters, Rollomatic,ANCA, Royces, Wendt, TGT, WIDMA etc. in the following industries / applications:- Rotary Tools- Cutting Tool Industries- Wood Working Tools- Tool Resharpening / Restoring- Optical Profile Grinding

L e t t h e s p a r k s f l y . . .


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Usage of Diamond and CBN wheelsIn general, diamond is used to grind Non- ferrous material as it reacts with ironwhereas CBN is used to grind Ferrous materials.

DIAMOND (D) CBN (CB)

Solid Carbide

Oxide Ceramics

Glass

Stone

Procelain, Stone Ware

Semi-conductors

Ferrite

Stellite- hard facing

Cast Iron

High Speed Steel

Tool Steel

Heat Treated Steel

Chromium Steel

Case Hardened Steel

Super Alloys

Bearing Steel

Stainless Steel

Inconel

APPLICATIONS WHEEL SHAPE

Fluting

Primary and secondary relief or end work

Gashing

Grinding top/bottom inserts

Grinding peripheral insertsOD grinding

Centerless grinding

Surface grinding

1A1,1V1,1F1

11V9

1V1, 12V9 30 or 45

6A2

2A2T

1A1, 1A1J

1A1, 1A1J

1A1

GRIT SIZE

USA FEPA

20/30

30/40

35/40

40/50

50/60

60/8080/100

100/120

120/140

140/170

170/200

200/230

230/270

270/325

325/400

D852

D602

D501

D427

D301

D252D181

D151

D126

D107

D91

D76

D64

D54

D46

COARSER

FINER

Shape Of Wheels1A1 14F1 14A1

3A1 6A2 1V1 9A3

6A9 11V9 12V9 1F1

2A2T

SAK Wheel Nomenclature

D64 B4 602SW

D: Abrasive Type S: Sak Abrasives64: Grit Size

B: Resinoid

602: Bond Type

2: Concentration

D: Diamond

CB: CBN

(FEPA Standard

D64-230/270,

D76-200/230 etc)

64:Finishing

126:Roughing

(25-1 ,50-2 , 75-3,

100-4. Etc)

601:Carbide, coolant with Oil, Face

602:Carbide, coolant with Oil & Water, Profiles

603:Steel, coolant with Oil & Water, profile & slicing

604: Steel, coolant with Oil & Water, ID, Face & Dry Grinding.

605:Carbide & Steel, coolant with Oil & Water, OD, ID,

Plunge, Surface, Centre less for Grit 325 and above

606:Carbide, coolant with water, OD, Plunge, Surface, Centre Less

W:Wet Grinding

D:Dry Grinding

Sak Abrasives Limited


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ANSI Wheel Shape Identification System

11 B 91 Choose basic core shape

2 Choose shape of abrasive cross section

3 Select location of abrasive section

1. Choose basic core shape

1. Periphery

2. Side

PRODUCT IDENTIFICATION

2. Abrasive Cross Sections And Marks

3. Location of abrasive section & marks

1

9

2

11

3

12 14

4 6

15

A AH B C CH D DD E EE

F FF G H J K L LL

M P Q QQ S

V YU

3. Both Sides

4. Inside Bevel

or Arc

5. Outside Bevel

or Arc

6. Part of periphery

8. Throughout

7. Part of side

9. Corner

10. Annular


Note: Solid black area indicates abrasive placement.


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TECHNICAL INFORMATION

Technical Guidelines

Spec Check

Avoid Excessive Feeds

Excessive feeds will result inpremature wheel wear.Excessive feed rates arecharacterized by:

- A hard grinding sound

- Chatter- Burn- High wheel wear rate- Vibration

Avoid Grinding Steel

Avoid steel when grinding withdiamond wheels. Keep theamount of steel ground to anabsolute minimum.

On brazed tools, use aluminumoxide wheel to back off the steelshank.

A high lubricity grinding fluidshould be used.

Use Rigid Work Support

All workpieces should besupported firmly during thegrinding process. Any amount ofvibration will cause wheel wearand produce chatter or wave

marks on the ground surface.

On work ground betweencenters, centerholds should beproperly prepared.

Minimize work overhang.

If the ground work is supportedby a work finger, ensure thefinger is strong enough toprovide vibration-free support.

Coolant Grind Wet

Diamond wheels should beused with a full flood coolantproperly directed towards thegrinding zone. Water with a rustinhibitor is recommended.

When flood application cant beused, try mist or spray application.

Use compressed air toatomize water or soluble oil.

Direct the spray at thegrinding zone to helpdissipate heat and preventheat damage to the work.

TROUBLESHOOTING GUIDE DRY GRINDINGPROBLEM POSSIBLE CAUSES SUGGESTED CORRECTION

Burning (excessive heat)

Chatter

Poor finish

Wheel loaded or glazed

Excessive feed rate

Wheel too durable

Wheel out of truth

Grit size too coarse

Excessive feed rate

Dress wheel with a dressing stick

Reduce infeed of wheel or workpiece

Use freer cutting specification or slow down wheel speed

True wheel; ensure it is not slipping on mount

Select a finer grit size

Reduce infeed of wheel or workpiece

SUGGESTED CORRECTION

Re-dress wheel

Apply coolant directly to wheel/workpiece interface

Reduce downfeed and/or crossfeed

Apply coolant to flood wheel/work surface

Increase wheel speed (observe maximum operating speed)

Use lighter dressing pressure

Change grit or grade; use higher concentration

Dress lightly until wheel opens up

Dress lightly until wheel opens up

Increase coolant flow to keep wheel surface clean

Never run wheel with coolant turned off

True wheel; ensure it is not slipping on mount

Increase feed rate; increase wheel speed

(Do not exceed wheel MOS)

Use lighter dressing pressure

Stop dressing as soon as wheel starts to consume stick rapidly

Select a finer grit size

Apply heavy flood so it reaches wheel/work interface

TROUBLESHOOTING GUIDE WET GRINDING

PROBLEM POSSIBLE CAUSES

Burning (excessive heat)

Short wheel life

Wheel will not cut

Chatter

Slow cutting

Poor finish

Wheel glazed or loaded

Poor coolant placement

Excessive material removal rate

Incorrect coolant flow

Low wheel speed

Excessive dressing

Wheel too soft or too hard

Glazed by truing

Wheel loaded

Wheel out of truth

Low feeds and speeds

Excessive dressing

Grit size too coarse

Poor coolant flow or location

7000

6000

5000

4000

3000

2000

1000

0

MATERIAL HARDNESS SCALESuperabrasives is a term used to describe thoseabrasives of extreme hardness which produceoutstanding results when properly used onspecific applications. The following chart provides ahardness comparison (Knoop Hardness Scale)between diamond and CBN superabrasives,aluminum oxide and silicon carbide standardabrasives, and some common materials theseabrasives are used to grind.

Diamon

d

Polycrys

talline

Diamon

d

CBNAbr

asive

Polycrys

talline

BoronN

itride

Vanadiu

mCarb

ide

SiliconC

arbide

Abrasiv

e

SiliconC

arbide

Aluminum

OxideA

brasive

Tungste

nCarbid

e

HardSt

eelHrc Gla

ss

SoftSte

elHrb8

5

Knoop

Hardness(H.K.)


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RECOMMENDATIONS & GUIDELINES FOR SELECTION OF CONCENTRATION INRELATION TO GRINDING FORCES

Three factors affect the choice of Abrasive grit:

GRINDINGFACTORS

AREA OF CONTACT BETWEENWHEEL & WORKPIECE

PROFILE &EDGE STRENGTH

CUTTING EFFICIENCYSOFT GRINDINGBOND

Concentration Low High

Large Small

High High

Hard

Low Low

Soft

Quantity of material to be removed

Surface-finish and wheel life

Material removal and wheel life

Surface Finish

Permissible Cutting Depth

Surface Finish Vs Grit Size

Depend on the adjustment when oscillation grinding, and (on pass and in-feed depth) when plunge-grinding.A wheel used properly shows a grit penetration depth equal to 1/5 - 1/8 of the grit dimension.If the level of roughness needed is known, it is possible to choose the right grit using the following charts:

For Oscillation Grinding

Selection Guideline for Grinding of Carbide & Ceramics

D

46

D

213

D

181

D

151

D

126

D

107

D

91

D

76

D

64

D

54

FEPA grit size

Cutting

Depth

0.04

0.035

0.03

0.025

0.02

0.015

0.01

0.005

mm

181

107

76

54

157

AA[]

Ra[]

Swiss2

0,05

N23

0,1

N38

0,2

N416

0,4

N532

0,8

N664

1,6

N7125

3,2

N8

(cutting speed approx.: 25m/sec - table speed 15m/min - coolant emulsion)


The Concentration specifies the carats of theabrasive grain (Diamond or CBN) processed in

3the 1cm abrasive layer.

The Concentration influences the performance of theDiamond and CBN Grinding tools becisively.It effects:

The service life of the grinding tools.

The stock removal rateProfile retention

The dimensional constant of the machined work piece.

The finish smoothness of the machined work piece.The price of grinding tool.

Concentration


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Expected Surface Finish by Grit SizeUse these charts as guides only. Surface finish is affected by several variables: machinetype and condition, type of material ground, coolant, wheel speed, bond system, etc.

DIAMOND

CBN

GRIT SIZEEXPECTED FINISH

WITH OSCILLATIONEXPECTED FINISH

MICRON Ra

GRIT SIZE

100

120150

180

220

320

400

100

120

150

180

220320

400

EXPECTED FINISHMICRO INCH AA

24 - 32

16 - 1814 - 16

12 - 14

10 - 12

8

7 - 8

35 - 40

30 - 35

25 - 30

20 - 25

15 - 2010 - 15

4 - 8

0.875 - 1.000

0.750 - 0.875

0.625 - 0.750

0.500 - 0.625

0.375 - 0.5000.250 - 0.375

0.100 - 0.200

EXPECTED FINISHMICRON Ra

0.60 - 0.80

0.40 - 0.450.35 - 0.40

0.30 - 0.35

0.25 - 0.35

0.20 - 0.25

0.18 - 0.20

DRY GRINDING

WHEEL SPEED CALCULATION:

CUP WHEELS

CUP WHEELS

PERIPHERAL WHEELS

PERIPHERAL WHEELS

Diamond Grinding Wheels

Diamond Grinding Wheels

To convert m/s to SFPM

To convert SFPM to M/S

To convert RPM to SFPM

Resin Bond Wheels

Resin Bond Wheels

11V9, 12V9, 15V9, etc.

11V9, 12V9, 15V9, etc.

Multiply M/S x 196.85 = SFPM

Divide SFPM by 196.85 = M/S

Multiply wheel diameter in inches x RPM x 0.262

4921 to 7874 SFPM

25 to 40 m/s

2756 to 3543 SFPM

14 to 18 m/s

1A1, 1V1, 1A1R, etc.

4921 to 7874 SFPM

25 to 40 m/s

CBN GRINDING WHEELS

Resin Bond Wheels 5906 to 9843 SFPM

30 to 50 m/s

5906 to 9843 SFPM

30 to 50 m/s

1A1, 1V1, 1A1R, etc.

2756 to 3543 SFPM

14 to 18 m/s

CBN GRINDING WHEELS

Resin Bond Wheels 2953 to 5906 SFPM

15 to 30 m/s

2953 to 5906 SFPM

15 to 30 m/s

M/S= Meters/secondRPM= Revolutions Per MinuteSFPM= Surface Feet Per Minute

Recommended Wheel Speeds for Diamond and CBN Wheels

WET GRINDING


EXPECTED FINISHPLUNGE

40 - 45

35 - 40

30 - 35

25 - 30

20 - 2515 - 20

5 - 10

MAXIMUM DEPTH OF CUTPER PASS FOR GRIT SIZE

0.001 - 0.002

0.001 - 0.0020.001 - 0.002

0.0007 - 0.001

0.0007 - 0.001

0.0004 - 0.0006

0.0003 - 0.0005

INCH

0.025 - 0.051

0.025 - 0.0510.025 - 0.051

0.018 - 0.025

0.018 - 0.025

0.010 - 0.015

0.008 - 0.013

MM


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Marketing Office

SP Infocity, 40, MGR Salai,

Perungudi, Kndanchavadi,Chennai - 600 096

Phone: 91-44-2454 3500

Fax: 91-44-2454 3510

Factory

Phone: 91-44-2792 3104

Fax: 91-44-2792 3009

B-49/W, Sipcot Industrial Complex,

Gummidipoondi - 601 201

Email US

INTERNATIONAL

[email protected]

INDIA

[email protected]

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