Sintered (Metal Bond)
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.
Advantages:
- Strong Retention of Diamond Crystals
- Lower Wear
- Long Life
- High Level of Consistency
- Highest Grade Diamond can be used
- Used at Lower cutting speeds
- Most Universal bond type
- Can be used on Higher horse power equipment
Example of strong and blocky shape (high quality) diamond crystals that can be used in Sintered (metal bond) diamond tools
All types and forms of diamond tools are available with this bond matrix. Such as diamond wheels used for grinding, diamond cut off wheels use for cutting, slotting, grooving, diamond core drills and bits used for drilling, reaming and milling. Diamond router bits, carving points and form tools used for shaping and forming. Complex tool shapes can be made, angles and radiuses ground to fit customers objectives. High precision tolerances can be maintained through precision grinding of the tools faces. Large variety of diamond grit sizes from 20 to 9,000 mesh can be used in conjunction with diamond concentration as low as 12 to 100 con, along with different bond harnesses, bond matrixes, and diamond crystal types to achieve the clients desired surface finish, cutting speed, tool life and consistency.
Benefits
- Better Surface Finish
- Less Chipping
- Minimum & No Material Deformation
- No Glazing
- Minimum Heat Generation
- Faster & Freer Cutting Action
- Beter Value
- Universal Application
- Longer Life
- Precision Tolerances
- Easy to Use
- Almost Unlimited Number of Options
- Custom Manufacturing
- Faster Return On Investment
Features
- Built for endurance and form-holding performance
- Enhanced wheel life and form retention
- Variety of grit sizes ranging from 300 to 3 microns for desired surface finish, cutting speed, and tool life
- Available in diameters ranging from .020″ (.5mm) to 20″ (500mm)
- Stock program of popular wheels used across many different applications
- Custom specifications can be produced per your requirements with short lead times
CHARACTERISTICS OF
Sintered (Metal Bond) Diamond & CBN Tools
- Form Holding: excellent
- Lifespan: Very High
- Cutting Action: Good
- Material Removal Rate: Limited
- Can be used Dry: No (only on select applications)
- Cost: Medium/High
- Main Bonding Agent : Bronze, Cobalt, Other Metal Powders
- Dressability: Average
- Hardness: Hard
- Required RPM's: Low
- Shape of Diamond Used: Blocky Crystal
How SMART CUT® Sintered (Metal Bond) Bond Works?
Sharpest And Finest Quality Diamonds
The newly exposed diamonds don't effect diamonds already working on the material. Unlike many other diamond bonds, diamonds in a SMART CUT® Bond remains sharp and grow sharper with each cut, prolonging product life and consistent performance.
Diamonds or CBN Crystals
Diamonds or CBN Crystals are activated only at the exposed layer. As Bond Matrix layer begin to wear out, diamonds in a new Bond Matrix layer are immediately activated, substituting the already used up diamond layer. The SMART CUT® Diamond Hybrid Bond makes sure every diamond is in the right place and at the right time, working where you need it most.
Advanced Formulated Open Diamond Bond Design
This advanced formulated open diamond bond design insures minimal chipping, fast cut, constant speed of cut, minimal cutting noise, and most important of all, consistent performance.
Sintered (metal bond)
Diamond Tools
Diamond & CBN Tools
Standard, Sintered (Metal Bond)
Sintered (metal bond) Diamond & CBN Tools
Capabilities & Specifications
- Diameters Available: 0.3mm to 1219mm
- thicknesses available: .004" (100 microns) to any thickness in .0005” (5micron) increments
- arbor sizes available (inside diameters): any arbor size. Standard are 1/8”, ¼”, 3/8”, ½”, 5/8”, ¾”, 1”, 1.25”, 40mm, 2.75”, 3.5”. For most wheels we can alter the arbor size to anything you need, almost same day and can also produce any arbor size. Wheels mounted on straight shank & mandrel available
- diamond type: synthetic diamond, synthetic coated diamond & cbn (cubic boron nitride)
- diamond depth (diamond height): 1.58mm to 20mm and fully impregnated with diamond (from OD to ID)
- Edge Type: Continuous Rim and Slotted
- Core Available: Steel, Stainless Steel, Bronze, Steel with Memory, High carbon steel, tungsten carbide, fully impregnated with diamond
- Edge Shape: 1A1R, 1A1, 1E1, 1M1, 1N1, 1V1, 1A8, 1E8, 1zm8, 1N8, 1V8 1A1, 14U1, 6A2, 6A2 SP, 9A3, 12A2-45, 11V9-70, 12S2-45SS, 12V5-45 (other kerf angles & radiuses can be produced upon request)
- Bond Hardness: Super Soft, Soft, Medium, Hard
- Tolerances Available: ODT tolerances +.050/.000 Arbor Hole Tolerance+.001/-.000 Rim Thickness +.002/-.001 Core Thickness: +.001/-.001
- diamond grit sizes: 25 mesh to 3 microns
- diamond concentration: low, medium & high (from 10 con to 150 con)
Contact Us for FREE Quote & Recommendation
Why Work With Us?
Comprehensive Source of Information on Diamond & CBN Blades
The more you understand about what we can do for you, the better our partnership will be. On our website you will find the Most Comprehensive Source of Information on Everything you wanted to know about diamond dicing blades & industrial diamond tools.
Large Inventory & Custom Manufacturing
Largest Inventory of Precision & Ultra Thin Diamond Dicing Blades in the U.S. Available in different sizes, thickness, arbor sizes, diamond concentrations, diamond mesh sizes, and bond hardness's.
Experience makes all the Difference
"ONE OF THE MOST EXPERIENCED COMPANIES IN THE INDUSTRY"
Over the years we have enjoyed working with all types if clients, regardless of size. Proprietary dicing blade chemistry, precision manufacturing methods, modern quality control methods, allow us to control and regulate the dozens of variables that affect blade life, quality of cut, surface finish. Reducing and often eliminating additional steps often required after cutting.
Umatched Technical Support
We Are a Partner In Your Success
Developing close ties with our customers is the foundation of our business. At the core of
our company is a team of world class engineers, knowledgeable customer service personnel here to serve you. Whether is designing or manufacturing a special solution. We will go out of our way to optimizing your process to ultimate level of efficiency.
Advanced
Technology
American Manufacturer As one of the few remaining independent U.S.Diamond Tool & machine builders. We have the experience & tradition to help you remain at frontier of technology Our experience has been further enhanced by acquiring assets and processes from some of the oldest American tool manufacturers, along with their decades of experience and R& D. This has positioned us as one of the most experienced companies in the industry.
Superior Quality &
Consistency
Our unique bond formulations, tool designs, stringent requirements, and utilization of exceptionally high-quality diamonds and raw materials ensure top-notch products that adhere to strict ISO 9000 standards.
Our proprietary technology allow us to control and regulate the dozens of variable that affect toolife, quality, & consistency
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What you should know
your next diamond tool?
How to Selecting Right Diamond Tools for your application
How to properly use Diamond Tools
Why use diamond
Diamond vs CBN (cubic boron nitride) Tools
What is Diamond Mesh Size and how to select best one for your application
What is Diamond Concentration and which to use for your application
