Choosing The Correct Diamond Bond Type
What is Bond Matrix?
The bond is the agent that keeps the diamond or CBN (cubic boron nitride) crystals in place. Its a matrix that consists of various powders (whether metal, phenolic resin or ceramic). Its job is to release the diamond crystals it hold in a controlled rate to obtain the clients desired objectives. Whether its best surface finish quality, fast cutting speed (certain yield), and long life (economics/return on investment). The diamond itself does the actual cutting. Bond matrix function is to retain and expose diamond. These two goals can often contradict and even interfere with each other. However, choice of the right bond grading assures that the diamond grit will be held until the maximum cutting value has been obtained.
If its too hard, dull diamonds will be held tool long resulting in glazing of the tool which means slow cutting and loss in productivity. For example a hard bond matrix can retain diamond crystals by burying them. If the bond is too soft, the bond matrix will lose diamond crystals by overly exposing them, resulting in premature loss and hence short tool life
The indication of this premature loss of diamond is deep pocket left behind. The presence of many pockets means the diamond is wasted without being used. Each diamond must protrude high to cut fast with low resistance. In order to cut efficiently not only diamond must be strong enough to withstand the impact, but also it should be adhered in the matrix firmly. Penetration into the material must be deep enough to allow the micro chipping, but shallow enough to prevent diamond shattering.
In order to keep distinct difference between these two goals the diamond is frequently coated or brazed in order to improve its retention so the matrix wear rate can be independently adjusted to allow the diamond to protrude properly.
Function of Bond Matrix in Diamond Tools
1. Diamond Crystal Retention Without Premature Pullouts
2. Controlled Bond Erosion for Diamond Exposure
3. Strength for Optimal Energy Transfer
Diamond & cbn bonds can be further classified based on if its single or multiple layered. A single layer bond is a coating with only one layer of diamond crystal attached to steel body. Once that layer of diamond crystal is worn, the tool is finished. Multiple layered bond has usually hundreds of bond layers impregnated in the bond matrix, when one layer of crystal wears, looses its sharp point, disintegrates and falls out. A new layer of fresh diamond crystal protrudes and starts working in the cutting zone, taking its place.
The choice between single-layer and multiple-layer diamond bonds depends largely on the specific requirements of the application, including the expected tool life, the nature of the material being processed, and economic considerations. Single-layer bonds offer precision and cost-effectiveness for smaller, detailed tasks, whereas multiple-layer bonds provide durability and sustained performance for extensive and demanding cutting operations.
Single-Layer vs. Multiple-Layer
Single-Layer Bonds
Structure and Composition: In single-layer bonds, a single layer of diamond crystals is electroplated or brazed onto a metal substrate, typically steel. The diamonds are held in place by a metal layer that coats the base. There are no additional layers of diamonds beneath the surface.
Operational Characteristics: The performance of single-layer tools is directly linked to the exposed diamonds. Once these diamonds are worn down or fall out, the tool’s effectiveness diminishes, and it cannot be used further unless re-coated.
Applications: Single-layer diamond tools are often used for specialized applications where precision and control are paramount. They are ideal for intricate cutting, detailing, and finishing work, particularly in materials like ceramics and composites where minimal tool pressure is required.
Advantages: Provides high precision due to the uniform exposure of diamond particles. It is also cost-effective for small or intricate tasks where a controlled cut is more important than tool life.
Limitations: The major drawback is the shorter lifespan compared to multiple-layer tools. Once the diamond layer is worn, the tool must be replaced or re-coated, making it less suitable for heavy-duty or large-volume applications.
Multiple-Layer Bonds
Structure and Composition: Multiple-layer bonds contain several layers of diamond crystals embedded within a bond matrix, typically made from metal, resin, or vitrified materials. As the outer layer of diamonds wears out, new layers of sharp diamonds are exposed, continually renewing the tool’s cutting surface.
Operational Characteristics: These tools are designed for longevity and continuous use. The depth of the diamond layers can vary, often containing hundreds of layers, allowing for extensive use over time. As diamonds on the outer layer become dull and disintegrate, fresh, sharp diamonds from the underlying layers protrude to maintain cutting efficiency.
Applications: Multiple-layer diamond tools are extensively used in heavy-duty applications such as grinding concrete, cutting hard stones, or in any operation where prolonged tool use is necessary.
Advantages: Extended tool life and enhanced durability make these tools more cost-effective for large-scale and intensive cutting operations. The continuous exposure of new diamonds minimizes downtime due to tool changes and maintenance.
Limitations: The initial cost of multiple-layer tools can be higher due to the complexity of their manufacturing process. Additionally, the cutting performance may slightly vary as new layers are exposed, requiring adjustments in operating parameters.
Factors Influencing Bond Type Selection: Material Characteristics
When selecting the appropriate diamond bond type for machining, understanding the characteristics of the material to be processed is crucial. The hardness and abrasiveness of the material directly impact the bond choice. Hard materials like tungsten carbide or hardened steels require a robust bond such as metal or vitrified, which holds the diamonds firmly to avoid premature wear and ensures the longevity of the tool. Conversely, softer and more abrasive materials, such as certain ceramics and composites, demand a bond that allows for quicker diamond exposure and more frequent renewal of the cutting surface, making resin bonds a suitable choice due to their balance between wear resistance and diamond replenishment.
Moreover, the thermal and chemical properties of the material significantly influence the selection of the diamond bond. Materials that generate considerable heat during machining or those that are chemically reactive with carbon, such as titanium and nickel-based alloys, necessitate bonds that can withstand high temperatures and resist chemical attack.
For instance, vitrified bonds are valued for their thermal stability, which helps prevent damage to both the tool and workpiece from excessive heat. Metal bonds are advantageous in scenarios where high thermal conductivity is essential for dissipating heat efficiently, thereby protecting the diamond grits from thermal degradation.
In environments involving chemically reactive materials, opting for chemically inert bonds like certain specialized metal or resin formulations is essential. These bonds prevent the chemical degradation of the diamonds, extending the tool’s operational life. Additionally, in conditions where the machining environment itself may be corrosive, selecting bonds that incorporate corrosion-resistant materials or protective coatings can further enhance the durability and effectiveness of the diamond tool.
Desired Outcomes: Influence of Diamond Bond Type on Machining Results
Surface Finish and Precision
Material Removal Rate
Machine Compatibility: Selecting Diamond Bond Types Based on Equipment Specifications
Tool Holding and Machine Power
Operational Speeds
Cost Efficiency: Evaluating the Economic Impact of Diamond Bond Choices
Initial Cost vs. Operational Lifespan
Maintenance and Replacement Costs
Strategic Considerations for Cost Efficiency
Selecting the right Bond Hardness
Right Bond Hardness
Bond too Hard
Bond too Soft
Diamond & CBN Bond Types Available
The selection of a bond type for diamond and CBN tools is a crucial aspect that directly influences their performance and suitability for specific applications. The following bond types are commonly used in the production of diamond tools:
Each bond is manufactured through unique technological processes, utilizing various bonding materials, additives, and types of diamond crystals. Consequently, every bond type has its distinct properties, strengths, and weaknesses, making it more or less suitable for certain applications. The choice of bond type depends on several factors, including the client’s objectives, the material being processed, the equipment used, and the overall operational environment. Therefore, collaboration between the client and the diamond tool manufacturer is crucial to ensure that the bond type and its characteristics are optimally matched to the specific application.
The client must provide detailed information about their needs, materials, and equipment, while the manufacturer uses their expertise and analytical experience from previous projects to determine the optimal tool parameters. These parameters include diamond grit size, concentration, bond hardness, and more. However, it is essential to recognize that tools with the same specification can behave drastically differently depending on the bond type used. What works well for one bond type might be entirely unsuitable for another.
For instance, a 120-mesh resin bond diamond cut-off wheel may offer an ideal combination of cutting speed and surface finish for glass or ceramic tubing. However, the same 120-mesh grit in a sintered (metal bond) wheel would produce excessive chipping, reducing cut quality. To match the surface finish and chipping level of a resin bond wheel, a metal bond wheel would typically require a finer grit size (such as 600-mesh) and a higher diamond concentration. Even then, it would be challenging to achieve the same surface finish and cutting speed provided by the resin bond. This is akin to comparing apples to oranges—while both are fruits, they differ significantly in characteristics and suitability for specific needs.
Diamond Tools
Sintered (Metal Bond)
UKAM Industrial manufactures and offers many types and forms of sintered (meta bond) diamond & cbn tools. Such as diamond wheels used for grinding, diamond cut off wheels use for cutting, dicing blades for singulation, diamond slotting wheels, drills, core drills, forming tools etc. Complex tool shapes can be made, Large variety of Diamond & CBN grit sizes from 300 to 3 microns can be used to achieve the clients desired surface finish, cutting speed, tool life and consistency. Diameters from small as .020″ (.5mm) to large as 20″ (500mm). Custom Tool specifications in this bond can be produced per your specification and requirements with short lead time.
About Sintered (Metal Bond)
Sintered (metal bonded) diamond tools have multiple layers of diamonds impregnated inside the metal matrix. Diamonds are furnaces sintered in a matrix made of iron, cobalt, nickel, bronze, copper, tungsten, alloys of these powders or other metals in various combinations. Metal bonded diamond tools are “impregnated” with diamonds. This means that selected diamonds are mixed and sintered with specific metal alloys to achieve the best cutting performance possible on any materials such as sapphire, advanced ceramics, optics, glass, granite, tile and etc. The metal bond surrounding the diamonds must wear away to continuously keep re-exposing the diamonds for the diamond tool to continue cutting. Sintered (metal bonded) diamond tools are recommended for machining hard materials from 45 to 75 on rockwell scale (5 to 9.5 on mohe’s scale of hardness).
SEM Image of Sintered (Metal Bond) Materix
Application of
Sintered (metal bond) Tools
Sintered (Metal bond) diamond tools utilize various metallurgical powders to firmly keep the diamond crystals in place, with minimum wear. The compacted materials are then hot pressed or sintered to full density. Heating rate, applied pressure, sintering temperature and holding time, are all controlled according to the matrix composition. This means that selected diamonds are mixed and sintered with specific metal alloys to achieve the best cutting performance possible large variety of materials. This bond type can utilize the highest quality and grade industrial diamonds (strong and blocky shape) monocrystaline particles. For this reason this bond family requires higher horsepower equipment and lower cutting speeds. Compared to their resin bond, nickel bond, braised bond, and vitrified bond counterparts. Sintered (Metal bond) is the strongest of all the bond families. Offering the longest life, greatest variety of specifications and fields of use available. While its not the optimum solution for all applications, Its one of the most widely used bond across most industries today.
Diamond & CBN Tools
Resin Bond
UKAM Industrial Resin Bond Diamond & CBN diamond tools are manufactured with advanced molding process. Available in a large variety of diamond, thicknesses, arbor/mandrel sizes, geometries, diamond sizes, diamond concentrations, and bond harnesses. Over a hundred resin bond formulations are available using hundreds of various fillers, diamond coatings, resins, molding pressures, curing cycles & temperatures. We have a stock program that includes most popular resin bond tool specifications for various industries and custom manufacture based on your requirements.
Application of
Resin Bond Tools
Recommended cutting, grinding and polishing hard, brittle or delicate materials including ceramics, glass tubing, optical glass, carbides, composites, silicon, magnetic materials, thermal spray alloys and exotic metals where low heat generation or improved surface finish is desired. Must be used at higher speeds. CBN, Resin bond Tools are recommended for cutting and grinding hard steels above Rc 60 at high speeds.
Advantages of
Resin Bond Diamond Tools
- Unmatched Cut Quality (eliminates secondary finishing operations)
- Faster & Freer Speed
- Less Heat Generation than other bond types
- Less Stress to material than other bond types
- Can be used dry (without coolant) when needed
- Can withstand Higher Temperature than sintered (metal bond) tools
- Perfect for fragile and delicate materials
- Minimize Chipping
- Improve Surface Finish
- Minimize Material Deformation
About Resin Bond
Its hardness, wear, heat resistance, diamond crystal retention and lubrication is controlled by use of various fillers organic and inorganic (usually ceramic or other metallic powders). Resin bond is low on Youn’s modulus, this gives it the free cutting characteristics for which this bond family is known. These properties is what gives this bond the fast cutting speeds, superior surface finish, and minimal chipping. Resin bond diamond tools are used at higher speeds, the most other bond families.
Resin bond diamond tools have shorter wheel life because the bond is much softer and brittle, and hence is not able to hold the diamond crystals in place as strong as its sintered (metal bond) counterpart.
Diamond & CBN Tools
Hybrid Bond
UKAM Industrial manufactures and offers many types and forms of Hybrid bond diamond tools. Such as diamond wheels used for grinding, diamond cut off wheels use for cutting, dicing blades for singulation, diamond slotting wheels, etc. Complex tool shapes can be made,
Large variety of Diamond & CBN grit sizes from 250 to 3 microns can be used to achieve the clients desired surface finish, cutting speed, tool life and consistency. Diameters from small as .080″ to large as 20″ (500mm). Custom Tool specifications in this bond can be produced per your specification and requirements with short lead time
Application of
Hybrid Bond Tools
Hybrid bond diamond and CBN tools find extensive utility in a wide range of applications including cutting, slicing, dicing, grinding, polishing, milling, slotting, beveling, and numerous others, where both resin bond and sintered (metal bond) diamond tools are conventionally employed. These versatile tools offer remarkable adaptability across various industries.
Hybrid Bond Tools excel in grinding carbide and HSS tools, ensuring precision and efficiency in tool manufacturing. They are also indispensable in the manufacturing of electronic devices, particularly for slicing and dicing blades such as the delicate and slender 1 A8 blades, whether in single blade or multi-blade configurations. Additionally, when it comes to achieving a mirror finish on read-write head sliders, which are composed of hard and brittle materials like alumina titanium carbide (Al2O. TiC), a two-step process involving a metal-bonded tool and subsequent polishing step with a resin-bonded tool is commonly employed. However, with the advent of hybrid bond blades specifically designed for this purpose, both the slicing and polishing operations can be seamlessly executed in a single operation, streamlining the manufacturing process.
Advantages of
Hybrid Bond Tools
- Longer tool life
- Minimum chipping
- Improved surface finish
- Better edge retention
- More consistent performance
Electroplated (Nickel Bond)
Diamond & CBN Tools
UKAM Industrial Superhard Tools manufactures Precision Electroplated Diamond Products from 0.5 microns to 20 grit (diamond mesh size) in Synthetic, Natural Diamond or CBN (cubic boron nitride). For a large variety of applications, materials, and industries.
We have a stock program that includes most popular electroplated specifications for various industries and custom manufacture based on your requirements.
Tools can produce just about any type or shape of electroplated tools, from print supplied by you, or we will plate a blank your provide
Advantages of Electroplated Diamond Tools:
- Free Cutting Action - better removal rates and less thermal damage to the part
- Good Form Holding Characteristics - -hold simple and intricate forms for the entire life of the tool or wheel, from first grind to last.
- Maximum Abrasive Particle Exposure
- High Stock/Material Removal Rates - Lower long term cost with the potential reduction or elimination of time associated with set-up, dressing and tool changes.
- Reusable - striped & replated with potential savings of 25% over new electroplated products.
About Nickel Bond
(Electroplated) Tools
Diamond & CBN Tools
Braised Bond
Application of Brazed Bond Tools
Brazed Bond Diamond Tools are perfect for machining tough-to-cut materials where fast stock removal and deep cuts are required. Including applications such as: non-metallic materials such as graphite epoxy, FRP, graphite, fiberglass, friction material, honeycomb and other composites.
Examples of Industries Used in
- Ophthalmic Lens
- Composites
- Construction
- Quartz
- Carbide
- Silicon
- Granite / Marble
- Fired and pre-fired Ceramics
- Plastics Industry
- Glass
- Graphite
- Ceramics (pre fired & post fired)
About Brazed Bond
Brazed Diamond Tools are produced using and process that creates a fusion between the diamonds and the metal bond. While they may appear similar to electroplated (nickel bond) diamond tools. They are produced utilizing completely different process. Brazed Bond Diamond Tools are produced inside vacuum oven at a high temperature, single layer of diamond crystal bonded to steel body with very high diamond exposure. Not only does it promote high diamond exposure, but it also eliminates the loss of diamond particles through pull-out. The diamond section will not strip or peel from the steel body. This translates into multiple benefits, including: aggressive tools that last longer, cut faster, run cooler and load less, providing increased productivity and part consistency.
Advantages of
Brazed Bond Diamond Tools
- Very fast & aggressive cutting speed
- Maximum diamond crystal exposure
- Ideal for hard to machine materials
- Strong retention of diamond grits
- Can be used at faster cutting speeds
- Can be used dry and tough environments
- Less Required Power
- Capability to Retain Form
- Minimizing & Often Eliminating Need for Dressing
- Ability to Strip and re-plate the tool (re-use)
- Lower Cost
Vitrified Bond
Diamond & CBN Tools
UKAM Industrial offers large variety of vitrified diamond & CBN Tools for many different applications. Vitrified bond tools are produced in a large variety of diamond, thicknesses, arbor/mandrel sizes, geometries, diamond sizes, diamond concentrations, and harnesses. High precision tolerances can be maintained. All vitrified bond tools are made to order.
Application of
Vitrified Bond Tools
Automotive parts grinding, Paper Manufacturing Industry, Bearing Industry, Aerospace industry, Turbine Industry, Grinding of PCD and PCBN, Profile grinding of TC threading plates, OD grinding of Printing Rolls, Shafts and Rods, Flat grinding of Ceramic components, Flat, OD and ID grinding operations of various parts, Grinding of Camshafts and Crankshafts, Finishing of turbine parts
Advantages of
Vitrified Bond Diamond Tools
- Very fast cutting speeds
- Best used for superhard materials
- Very free cutting
- Ability to control prosity
- Self dressing/sharping
- Primarily used for grinding applications
- Profile easily during grinding along edges
- Longer life than resin bond diamond tools
About Vetrified Bond
Vitrified Bond is a Fired Ceramic Bond matrix, which is very brittle and porous. Also known as ceramic bond. Based on fusible glasses combined with fillers and abrasive grains. Offers durability of sintered (metal bond), along with free cutting action of resin bond. Vitrified bond has higher bonding strength then resin bond. Vitrified bond diamond tools are free cutting, produce good surface roughness, have good wear resistance and retain straightness and form very well.
Diamond & CBN Bond Type Characteristics
Retention of Diamond/CBN Crystals
Bond Life
Surface Finish
Diamond/CBN Particle Exposure
Cutting Speeds
Dressing Frequency
Comparing Cost
Coolant Use
Application Across Various Industries
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Alexander Schneider is a senior applications engineer and leading authority in the industrial diamond tooling industry, with over 35 years of hands-on experience in the development, application, and optimization of ultra-thin and high-precision diamond blades, diamond core drills, and diamond and CBN grinding wheels. His work spans a wide range of advanced materials including ceramics, glass, composites, semiconductors, and high-performance metals.
Throughout his career, he has collaborated with leading R&D institutions, national laboratories, and high-tech manufacturing companies across Europe, North America, and Asia, providing technical expertise and tailored solutions for demanding cutting and surface preparation applications.
Mr. Schneider has played a pivotal role in advancing precision cutting, sectioning, dicing, and grinding technologies used in research, production, and failure analysis. He is widely respected for his ability to optimize tool design and cutting parameters to meet exacting industry standards—balancing factors such as cut quality, blade life, material integrity, and process consistency.
As an author, Mr. Schneider is known for delivering practical, application-focused insights that translate complex technical challenges into clear, actionable strategies. His articles and technical guides serve as trusted resources for engineers, researchers, and manufacturers seeking to improve precision, reduce process variability, and enhance tool performance in critical applications.