Diamond & CBN Wheels

Diamond & CBN Wheel Troubleshooting Guide

Diamond & CBN Wheel Troubleshooting Guide
02 Jun

Our illustrated troubleshooting guide was designed to help you optimize your grinding operations. It assists in diagnosing most possible issues that may arise when using diamond & CBN WHEELS. This guide highlights the signs to watch out for, their potential causes, their impact on cutting performance, and recommended solutions for resolving these issues and preventing them in the first place. Additionally, please be sure to explore our KNOWLEDGE CENTER articles. You can also contact our technical support for further assistance.

Problem

Possible Cause(s)

Suggested Solution(s)
SHORT WHEEL LIFE
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Signs: Wheels worn out in a very short period of time compared to normal life span
  • Excessive force on the wheel
  • Wheel grit is too fine for the application
  • Poor coolant quality or flow
  • Improper wheel storage leading to degradation
  • Reduce the feed rate or depth of cut to lessen the load on the wheel.
  • Choose a coarser grit that can withstand the workload.
  • Improve coolant concentration and flow; ensure the coolant system is not clogged.
  • Store wheels in a dry, temperature-controlled environment to prevent deterioration.
MATERIAL BURNING

Signs: Discoloration of the surface
  • Too high wheel speed or too deep a cut
  • Insufficient coolant
  • Inappropriate wheel bond for the material
  • Overly aggressive dressing leading to excessive wheel sharpness
  • Decrease wheel speed and cut depth.
  • Check coolant delivery and increase flow rate.
  • Use a wheel with a bond type suited to the material being ground.
  • Adjust the dressing parameters to ensure the correct balance between sharpness and strength of the wheel.

DIFFICULTY OF ACHIEVING PRECISON TOLERANCES

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  • Machine tool wear or lack of stability
  • Inconsistent wheel dressing or wear
  • Environmental changes affecting machine dimensions or workpiece material
  • Wheel is too soft and wears quickly, changing the geometry
  • Service machine to repair or replace worn components, ensure stability in the setup.
  • Use a consistent and precise dressing routine.
  • Control temperature and humidity in the grinding area to maintain consistent conditions.
  • Select a harder wheel that maintains its shape better for precision grinding.
DIFFICULTY DRESSING
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  • Diamond dresser is worn or improperly set
  • Wheel bond is too hard or abrasive is too tough
  • Insufficient coolant during dressing
  • Incorrect dressing parameters
  • Replace the diamond dresser if worn and ensure it is properly set.
  • Use a more appropriate dressing tool with suitable properties to effectively dress the wheel.
  • Provide adequate coolant flow during the dressing process to keep the diamond dresser cool and effective.
  • Adjust the speed, feed rates, and depth of dressing cuts to match the requirements of the wheel.
WHEEL DOES NOT MAINTAIN PROFILE
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  • Wheel bond is too soft, leading to rapid wear
  • Inadequate machine rigidity or vibrations
  • Incorrect dressing tool or technique
  • Wheel exposure to temperature variations or humidity
  • Use a harder bonded wheel to maintain profile shape over longer periods.
  • Strengthen the machine setup to reduce vibrations and increase rigidity.
  • Ensure the dressing tool and technique used are capable of effectively maintaining the wheel profile.
  • Maintain a consistent environment to prevent wheel shape distortion.
PREMATURE DIAMOND FRACTURE
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  • Too much pressure during grinding or dressing
  • Wheel speed is too high
  • Vibration or impact during use maintaining the wheel profile.
  • Reduce the infeed rate and optimize dressing pressure.
  • Lower the wheel speed to prevent excessive force on the diamond particles.
  • Eliminate sources of vibration and handle the wheel carefully to avoid impacts.
WHEEL GLAZING & LOADING
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  • Bond too hard for the material
  • Insufficient coolant
  • Wheel operating speed too low
  • Inappropriate dressing strategy
  • Use a wheel with a softer bond to allow new grains to be exposed more readily.
  • Increase coolant flow and ensure the nozzle is correctly positioned to target the grinding zone.
  • Increase the wheel speed within safe operating limits to improve cutting efficiency.
  • Adjust dressing parameters, such as tool type, feed rates, and speeds to be more aggressive and expose fresh abrasive.
WHEEL BREAKAGE
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  • Wheel dropped or damaged during handling
  • Over-speeding beyond the maximum RPM
  • Thermal or mechanical shock
  • Incorrect mounting or tightening
  • Handle wheels with care, use protective covers, and store them properly to avoid drops or impacts.
  • Never exceed the maximum RPM listed for the wheel. Always check machine settings before starting operations.
  • Avoid drastic temperature changes and ensure gentle engagement during grinding to prevent shocks.
  • Follow the manufacturer’s guidelines for correct mounting and use the proper flanges and tightening procedures.
POOR SURFACE FINISH
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  • Wheel is too coarse
  • Inadequate or improper dressing
  • Wheel imbalance
  • Vibration from machine or environment
  • Select a wheel with a finer grit to achieve a better surface finish.
  • Dress the wheel more frequently with the correct technique to ensure it presents the finest possible abrasive surface to the workpiece.
  • Balance the wheel properly on a balancing stand and ensure it is re-checked regularly.
  • Isolate the machine from external vibrations and check for any worn parts or instability in the machine itself.
MATERIAL WARIPING
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  • Uneven cooling or excessive heat during grinding
  • Inappropriate handling after grinding
  • Non-uniform material removal
  • Uneven fixture or clamping pressure
  • Ensure uniform cooling and consider using coolants with better heat dissipation properties.
  • Handle the workpiece gently post-grinding to avoid warping due to residual stresses.
  • Use consistent grinding practices and check for wheel balance and dressing regularity to ensure uniform material removal.
  • Check fixtures and clamping mechanisms to apply even pressure without distorting the workpiece.
WHEEL LOADING / MATERIAL STICKING
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  • Inadequate coolant flow or type
  • Grinding parameters too aggressive
  • Wheel bond too hard for the material
  • Contamination in the coolant system
  • Increase the coolant flow, improve nozzle placement, or switch to a coolant better suited for the material being ground.
  • Adjust the grinding parameters (e.g., reduce speed, feed rate) to prevent material from adhering to the wheel.
  • Switch to a wheel with a softer bond to improve self-sharpening action.
  • Clean the coolant system thoroughly and maintain coolant quality.
DIAMOND WHEEL SPINDLE INTERFACE ISSUES
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  • Wheel flanges are not properly torqued or aligned
  • Spindle or adapter damage
  • Incorrect wheel adapter size
  • Accumulation of dust and debris at the interface
  • Torque flanges to specifications and ensure alignment is correct.
  • Inspect the spindle and adapter for damage and wear; service or replace as needed.
  • Use the correct wheel adapter for the specific wheel size and type.
  • Clean the spindle and wheel bore before mounting to ensure a clean mating surface.
POOR FINISH OR SCRATCH ON MATEIRAL
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  • Wheel is contaminated with foreign material
  • Inadequate dressing of the wheel
  • Swarf or chips not being effectively cleared
  • Workpiece or wheel vibration
  • Clean the wheel using a wheel cleaner or a dressing stick to remove contaminants.
  • Increase the frequency and/or aggressiveness of dressing to ensure the wheel surface is clean and sharp.
  • Enhance the coolant flow and direction to ensure swarf is being cleared from the work area.
  • Check for and eliminate sources of vibration. Balance the wheel and ensure workpiece stability.
EXCESSIVE POWER CONSUMPTION
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  • Wheel is too hard or too dull
  • Excessive force during grinding
  • Machine alignment or mechanical issues
  • Motor or drive system inefficiencies
  • Use a softer or sharper wheel, or adjust dressing to maintain sharpness.
  • Decrease the feed rate or depth of cut to reduce resistance.
  • Check machine alignment and address any mechanical issues.
  • Service the motor or drive system to ensure they are running efficiently.
INCONSISTENT WHEEL PERFORMANCE
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  • Variability in coolant supply or temperature
  • Inconsistent dressing cycles or technique
  • Fluctuations in power supply
  • Changes in environmental conditions around the machine (temperature, humidity)
  • Monitor and stabilize coolant supply and temperature to maintain consistent performance.
  • Standardize dressing routines and ensure they are followed consistently.
  • Install power conditioners or uninterrupted power supplies to regulate the input power.
  • Control the environmental conditions in the grinding area to minimize their impact on the process.
DRESSING WHEEL WEARS OUT QUICKLY
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  • Excessive dressing pressure or speed
  • Dressing wheel not suitable for the diamond/CBN wheel
  • Diamond/CBN wheel bond too hard
  • Contamination or glazing on diamond/CBN wheel
  • Adjust the dressing pressure or speed to more moderate levels to extend the life of the dressing wheel.
  • Use a dressing wheel appropriate for the hardness and grit of the diamond/CBN wheel.
  • Use a softer bonded grinding wheel that requires less aggressive dressing.
  • Clean and dress the wheel more frequently to prevent contamination build-up.
OUT OF ROUND WHEEL
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  • Wheel has been dropped or mishandled
  • Improper mounting or balancing
  • Spindle or arbor runout
  • Uneven dressing
  • Inspect for damage and replace if necessary. Always handle with care.
  • Ensure wheel is mounted and balanced according to manufacturer's specifications.
  • Check and correct spindle or arbor runout to within acceptable limits.
  • Employ consistent and even dressing techniques. Use a high-quality dresser and make sure it's applied uniformly across the wheel's surface.
MATERIAL CHATTER MARKS
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  • Wheel imbalance
  • Loose or worn spindle bearings
  • Inadequate machine rigidity
  • Incompatible wheel specification for the workpiece material and grinding operation
  • Rebalance the wheel; check that wheel hubs and flanges are clean and flat.
  • Inspect and replace spindle bearings if needed.
  • Reinforce the machine setup; check for any components that need tightening or replacement.
  • Choose a wheel with the right specifications for the material and operation.
DRESSING WHEEL LIFE IS SHORT
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  • Incorrect dressing tool material for the wheel
  • Excessive pressure during dressing
  • Dressing tool speed is too high
  • Inadequate coolant during dressing
  • Use a dressing tool material that is harder and more wear-resistant, suitable for the wheel type.
  • Dress at lower pressures and increase the contact time if necessary.
  • Adjust the dressing tool speed to be appropriate for the diamond/CBN wheel.
  • Ensure an ample supply of coolant during the dressing process to prevent overheating and wear on the tool.
MATERIAL DISCOLORATION
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  • Too much heat generation during grinding
  • Wheel speeds and feeds too aggressive
  • Insufficient dressing leading to dull wheels
  • Contaminated coolant or inadequate coolant type
  • Improve coolant flow and use a wheel with more suitable bond strength and grain size to reduce heat.
  • Adjust the grinding parameters to be less aggressive and prevent overheating.
  • Increase the frequency of dressing to ensure the wheel stays sharp and efficient.
  • Use the correct type of coolant and maintain its cleanliness to ensure proper temperature management during grinding.
MATERIAL MICRO CRACKS
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  • Excessive grinding pressure
  • Wheel too hard or too fine
  • Poor coolant direction or flow
  • High-speed grinding without adequate cooling
  • Reduce infeed rates and/or adjust the traverse speed to minimize pressure.
  • Use a softer or coarser wheel to minimize sub-surface damage.
  • Optimize coolant delivery to directly target the grinding zone and improve cooling.
  • Adjust the grinding speed to match coolant capabilities or improve the coolant system.
DIAMOND OR CBN WHEEL EXHIBITS UNUSUAL WEAR
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  • Misalignment of the wheel to the workpiece
  • Unstable workpiece holding or clamping
  • Wheel grade too soft for the application
  • Presence of abrasive particles between wheel and workpiece
  • Align the wheel correctly to the workpiece to ensure even wear.
  • Check and improve the workholding setup to ensure stability during grinding.
  • Select a wheel with the appropriate grade and bond strength for the material and grinding conditions.
  • Clean the surface of the wheel and the workpiece thoroughly to remove any abrasive particles.
Uneven wear on the wheel's face
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  • Non-uniform dressing
  • Workpiece geometry causing uneven pressure
  • Inconsistent workpiece hardness
  • Coolant not reaching all areas of the grinding zone
  • Dress the wheel evenly and properly, ensuring consistent contact across the wheel's face.
  • Adjust workpiece clamping and support to distribute pressure evenly.
  • Pre-check workpiece material for uniformity before grinding.
  • Redirect coolant flow or use multiple nozzles to cover the entire grinding zone evenly.
WHEEL DOES NOT CUT EFFECTIVELY
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  • Glazed or loaded wheel
  • Wheel bond too hard
  • Insufficient horsepower or torque from the machine
  • Wrong wheel specification for the material
  • Dress the wheel to expose new abrasive grains. Increase dressing frequency.
  • Use a wheel with a softer bond to allow for easier grain breakout.
  • Check machine capabilities to ensure it is suitable for the operation. Consider a more powerful machine if necessary.
  • Match the wheel type and specifications to the material being ground.
DIAMOND / CBN LAYER COMING OFF
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  • High impact or shock to the wheel
  • Excessive heat generation
  • Poor wheel quality or manufacturing defects
  • Incorrect storage leading to thermal stress
  • Avoid dropping or hitting the wheel. Ensure smooth engagement with the workpiece.
  • Optimize coolant flow and grinding parameters to reduce heat.
  • Inspect wheels before use and only purchase from reputable suppliers.
  • Store wheels in a stable and controlled environment to avoid temperature fluctuations.
MACHINE VIBRATION AFFECTING FINISH
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  • Unbalanced wheel
  • Loose machine components
  • Worn or faulty machinery
  • External environmental vibrations
  • Balance the wheel on a balancing stand before mounting.
  • Inspect and tighten all machine components, including fixtures, tooling, and workholding devices.
  • Service or replace machine parts that are worn or malfunctioning.
  • Isolate the machine from other equipment and external sources of vibration. Use anti-vibration mounts if necessary.
DUST OR DEBRIS CONTAMINATION
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  • Inadequate dust extraction system
  • Open windows or doors causing drafts
  • Operators not following clean working practices
  • Nearby operations creating debris
  • Ensure the dust extraction system is working effectively and is properly positioned.
  • Minimize air movement around the grinding area by closing windows and doors.
  • Enforce clean working practices; use covers for machines when not in use.
  • Isolate grinding operations from other work that generates dust or debris.

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