Proper selection of the abrasive cutoff saw is essential to ensure the required part quality, productivity and overall cost per part. Although the type of abrasive particles is often the primary driving force for abrasive cutoff saw selection, the type of bonding can also play a key role in optimizing the abrasive cutoff saw operation.
Abrasive cutoff saw structure\ shows abrasive particles, bonding, porosity and filler composition.
As production technology requirements for increasingly tighter part tolerances and process flexibility become more stringent, abrasive offers many unique advantages for abrasive grinding wheels suppliers and small workshops. The emergence of new, difficult-to-machine materials has also prompted many companies to implement abrasive processes on other material removal technologies. However, the correct choice of abrasive cutoff saw is critical to ensure the required part quality, productivity and overall cost per part. Although the type of abrasive particles is often the primary driving force for abrasive cutoff saw selection, the type of bonding can also play a key role in optimizing the abrasive operation.
First, the abrasive is generally considered to be the main component and may be a conventional oxide or other ceramic material, diamond or cBN (cubic boron nitride). The bonding medium retains the abrasive particles within the wheel structure and provides overall strength. Free space or porosity is intentionally left in the abrasive cutoff saw to enhance the delivery of coolant and provide chip accommodation during the abrasive process. In addition, depending on the end use of the abrasive cutoff saw and the type of abrasive product, specific fillers are sometimes included. The number of each of these wheel assemblies can be adjusted to the needs of a given application and together form a complex and powerful composite that is intended to produce a target surface.
Abrasive product binders are generally classified as organic (resin, rubber, etc.), vitrified (glass or glass ceramic) or metal, and each binder has its own unique advantages. Organic or resin bonding provides much greater flexibility (inverse stiffness) than other types, and can withstand harsh abrasive conditions such as vibration and large lateral forces. These properties make organic binders particularly useful for high removal rough abrasive applications such as steel conditioning or abrasive cutting operations. They are also advantageous for precision abrasive of superhard materials such as diamond or hard ceramics. When precision abrasive a ferrous metal material such as hardened steel or a nickel-based alloy, the vitrified bond has excellent dressability and machinability. The ceramic bond is specifically designed to provide strong adhesion to cBN particles through chemical bonding agents, resulting in a G ratio (volume ratio of scrap to wheel wear) of 10,000 or higher. Metal bond has excellent wear resistance and styling ability. They range from single-layer products (plating) to multi-layer wheels and can be made into very strong and dense wheels. The metal bond wheel may be too hard to be effectively trimmed and is typically used in retrofit machining centers that do not have wheel hub finishing capabilities. However, newer brittle metal bond abrasive cutoff saws can be trimmed in a similar manner to vitrified abrasive cutoff saws and have the same beneficial properties as sandless abrasive. The G ratio (volume ratio of scrap to wheel wear) is made 10,000 or higher. Metal bond has excellent wear resistance and styling ability. They range from single-layer products (plating) to multi-layer wheels and can be made into very strong and dense wheels. The metal bond wheel may be too hard to be effectively trimmed and is typically used in retrofit machining centers that do not have wheel hub finishing capabilities. However, newer brittle metal bond abrasive cutoff saws can be trimmed in a similar manner to vitrified abrasive cutoff saws and have the same beneficial properties as sandless abrasive. The G ratio (volume ratio of scrap to wheel wear) is made 10,000 or higher. Metal bond has excellent wear resistance and styling ability. They range from single-layer products (plating) to multi-layer wheels and can be made into very strong and dense wheels. The metal bond wheel may be too hard to be effectively trimmed and is typically used in retrofit machining centers that do not have wheel hub finishing capabilities. However, newer brittle metal bond abrasive cutoff saws (such as Norton Paradigm) can be trimmed in a similar manner to vitrified abrasive cutoff saws and have the same beneficial properties as sandless abrasive. They range from single-layer products (plating) to multi-layer wheels and can be made into very strong and dense wheels. The metal bond wheel may be too hard to be effectively trimmed and is typically used in retrofit machining centers that do not have wheel hub finishing capabilities. However, newer brittle metal bond abrasive cutoff saws