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7/25/2019 Super Catalogue
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7/25/2019 Super Catalogue
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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
Sak Abrasives Limited
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)
Sak Abrasives Limited
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
Sak Abrasives Limited
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
exports@sakabrasives.com
INDIA
super@sakabrasives.com
w w w . s a k a b r a s i v e s . c o m
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