You should pick the right structure of grinding wheel for your job. This choice can really change how well you grind. If you match the grinding wheel structure to your material, you work better. You also get a smoother finish. Studies show that the right grinding wheel structure helps a lot. Adding pores or special patterns can control heat. It also helps remove chips and makes your work better. If you use cbn wheels for hard jobs or want a smooth finish, the right structure will help you. Think about how fast you want to remove material, the finish, and heat control before you start grinding with cbn or any other grinding wheel.
Key Takeaways
Pick the grinding wheel structure by thinking about your material, job, and finish goals. This helps you get the best results. Open structure wheels are good for fast material removal. They also keep things cooler when grinding soft materials. Medium structure wheels give a good mix of speed, finish, and durability. They work well for most grinding jobs. Dense structure wheels are best for high precision and smooth finishes. They are great for hard or brittle materials. Always use coolant and dress your wheel the right way. This helps control heat, keeps your work safe, and makes your wheel last longer.
How to Choose
Identify Material
First, know what material you will grind. Different materials need different grinding wheels and cbn types. In factories, you might use:
Nonferrous metals like aluminum, copper, and zinc
Each material acts differently when you grind it. For example, aluminum oxide is best for steel and bronze. Silicon carbide works better for softer things like rubber, glass, or aluminum. Zirconia alumina is strong and good for steel alloys. Ceramic aluminum oxide is used for tough steels. Picking the right grinding wheel helps you get a good finish and control how much material you remove.
Define Application
Next, think about what you will do. Are you doing surface grinding, cylindrical grinding, or tool grinding? Each job needs a special way. Surface grinding needs a wheel for a smooth finish. Cylindrical grinding is for round parts and close sizes. Tool grinding often uses cbn wheels for hard tool steels. The job you do changes which grinding wheel and cbn structure you pick. Open structure wheels are good for hard materials and fast material removal. You should dress your wheel often to keep it sharp.
Set Finish Goals
Set your finish goals before you start. Do you want a rough or smooth finish? Precision grinding in places like aerospace or medical needs very close sizes, sometimes as close as ±0.001 mm. To get these finishes, pick the right grinding wheel, control your speed, and use cbn wheels if needed. Keep your work area clean and use coolant to stop overheating. A good finish helps your parts last longer and work better.
Check Machine and Coolant
Your machine and coolant system are important for grinding. Heavy grinding wheels can be hard on your machine, so lighter wheels may be better. The coolant you use also matters. Oil-based coolants lower grinding forces and help your cbn wheel last longer. Coolant pressure and flow help control heat and remove chips. Good coolant keeps your grinding wheel clean and helps you reach your finish and material removal goals.
Tip: Always match your grinding wheel, cbn type, and coolant to your machine and job for the best results.
Structure of Grinding Wheel
What Is Structure?
You need to understand the structure of grinding wheel before you choose the right one. The structure of grinding wheel means how the abrasive grains and the bonding material are arranged. This setup affects how well you can do grinding, how much material you remove, and the quality of the surface finish. You measure the structure by grit size and grade. Grit size tells you how big the grains are. Lower numbers mean bigger grains that cut fast but leave a rougher surface. Higher numbers mean smaller grains that work slower but give you a smoother finish. Grade shows how hard the bond is. Softer grades let old grains fall away and new sharp grains appear. Harder grades last longer and work well when you need to remove a lot of material or when you want more precision.
Open Structure
Open structure of grinding wheel has more space between the grains. You get better chip clearance and cooler grinding. This helps you when you want to remove metal fast or work with soft materials like aluminum. Open structure wheels also help control heat, so you avoid burning the surface. If you use cbn wheels for rough grinding, open structure gives you speed and keeps your work cool. You will see less clogging, which means you keep your finish more even. Open structure is not the best for high precision, but it works well for quick jobs.
Medium Structure
Medium structure of grinding wheel gives you a balance. You get some chip clearance and a decent finish. Many shops use medium structure for general grinding tasks. You can use it for both rough and precision work. If you need to grind with cbn wheels and want a mix of speed and finish, medium structure is a good choice. You get enough control over heat and can still reach a smooth surface. Medium structure works well for most materials and helps you keep your grinding process steady.
Dense Structure
Dense structure of grinding wheel packs the grains close together. You get more abrasive in each area. This setup gives you a finer finish and more precision. You use dense structure when you need to grind hard or brittle materials, like glass or ceramics. Dense wheels work best for cbn grinding when you want a perfect surface finish. You will see more heat, so you must use coolant to protect your work. Dense structure is great for jobs where surface quality and precision matter most, such as in tool making or when you need a mirror-like finish.
Tip: Use this table to compare the three structures and pick the best one for your grinding job:
Structure Type | Grain Spacing | Performance Characteristics | Suitable Materials |
|---|---|---|---|
Open | More space | Better chip clearance, cooler grinding, faster removal | Soft or ductile (e.g., aluminum) |
Medium | Intermediate spacing | Balanced finish, chip clearance, and precision | General purpose |
Dense | Less space | Finer finish, more heat, slower removal, high precision | Hard or brittle (e.g., ceramics) |
Types of Grinding Wheels
Conventional Types (Aluminum Oxide and Silicon Carbide)
There are many grinding wheels in shops and factories. The most common ones use aluminum oxide or silicon carbide. These grinding wheels work for many jobs. You can see their main uses in the table below:
Grinding Wheel Type / Bond / Grain | Description | Typical Applications |
|---|---|---|
Aluminum Oxide | Hard, cuts fast at first, good for steel and iron | Grinding steel, iron, and metals |
Silicon Carbide | Very hard, cuts fast, not as tough | Grinding soft metals like aluminum, alloys, and non-ferrous metals |
Ceramic Alumina | Very strong and hard, lasts long | Tool and die making, medical devices, aerospace, automotive parts |
Zirconia Alumina | Sharpens itself, tough, works on steel | Heavy pressure grinding on steel and stainless steel |
Zirconia Alumina + Ceramic Alumina Blend | Very hard, resists wear, handles high heat | Tough grinding jobs that need strong wheels |
White Aluminum Oxide | Tough, handles heat, can be recycled | Grinding steel, stainless steel, glass, stone, plastic |
Resin Bond | Flexible, absorbs shock, removes a lot | Grinding jobs with lots of vibration |
Silicate Bond | Cuts with little force, very precise | Jobs that need a smooth finish |
Shellac Bond | Natural resin, used for small wheels | Precise jobs with low force, like sharpening tools |
Rubber Bond | Very stretchy, reduces shaking | Grinding fragile or easy-to-break materials |
Type 27 Wheel | Flat with a center dip, works at angles | Removing material at 25-35° angles |
Type 28 Wheel | Curved shape, best at low angles | Getting into tight spots, working at sharp angles |
You can use these wheels for many grinding jobs. Aluminum oxide wheels are best for steel and iron. Silicon carbide wheels cut soft metals and non-ferrous materials. Pick the right wheel for your job to get good results.
Superabrasive Types (Diamond and CBN)
You will also find superabrasive grinding wheels. These use diamond or cbn. Cbn grinding wheels have cubic boron nitride as the abrasive. You use cbn wheels for very hard materials. Cbn wheels last much longer than regular wheels. You will spend less time changing wheels and more time working.
Cbn wheels last a long time. You do not need to replace them often.
Cbn wheels keep their sharp edges. You get even and precise grinding.
Cbn wheels help you save money over time. They cost more at first, but you buy fewer wheels.
Cbn wheels are good for tight sizes and smooth finishes.
Cbn wheels resist heat. You can grind hard metals without damage.
Cbn wheels need less power. You get better cutting.
Cbn wheels keep their shape longer. You can grind more before fixing the wheel.
Cbn wheels use cubic boron nitride, almost as hard as diamond.
Cbn wheels are best for steel, superalloys, and other hard metals.
Cbn wheels give you high output and lower costs per part.
Diamond wheels are another superabrasive type. Use diamond wheels for grinding ceramics, glass, and carbide. Diamond is the hardest, but cbn wheels work better for steel.
Note: Pick superabrasive grinding wheels when you want long life, high precision, and top results.
Structure vs. Application
Metals
When you grind metals, you must pick the right grinding wheel structure. Ferrous metals like steel and cast iron need special care. You do not want too much heat or loading. A moderately open structure works well for these metals. This type lets chips move away and keeps things cool. Use tough abrasives like aluminum oxide or zirconia alumina for steel. These help keep your surface looking good. For cast iron, silicon carbide wheels cut fast and make less heat. This lowers the chance of damage and keeps your finish smooth. Cbn grinding wheels are great for hard steels. They give you high accuracy and last a long time. You get a better finish and less downtime when making many parts. Always match the structure and abrasive to your job for the best results.
Open structures cool better and clear chips quickly.
Medium structures balance chip clearing and cutting power.
Dense structures give a fine finish but can trap heat.
Tip: For most metals, medium or moderately open structures give the best mix of cooling, chip clearing, and surface quality.
Ceramics and Glass
Grinding ceramics and glass needs a different method. These materials are brittle and can break or chip easily. You need a grinding wheel that protects the surface and keeps it smooth. Resin-bonded diamond wheels work best for these jobs. They lower heat and stress on the material. Laser-structured wheels with special textures help even more. These designs can lower grinding forces by up to 54%. You will see fewer cracks and less chipping. Shark fin patterns on the wheel hold chips better and help the wheel last longer. You get a smoother finish and longer wheel life. For big jobs, these wheels keep your process steady and your finish high quality. Always use coolant to control heat and protect the surface while grinding.
Precision vs. Roughing
You need to match your grinding wheel structure to your goal. For roughing, you want to remove material fast. Open or medium structures are best for this. These types clear chips quickly and keep things cool. You get fast cutting and high removal rates. For precision work, you need a smooth finish and tight sizes. Dense structures or multigranular wheels help here. Multigranular wheels use grains of different sizes. This fills gaps and stops grain chipping. You get better chip removal and less wear. The surface stays smooth and you avoid deep scratches. Cbn grinding wheels are perfect for high precision jobs. They keep their shape and give steady quality. You can use them for round or flat grinding in precision work. In big jobs, these wheels save time and keep your finish top-notch.
Open structures: Best for roughing, fast removal, cooler grinding.
Dense or multigranular structures: Best for precision, smooth surface, less wear.
Surface Finish
Surface finish quality depends on your grinding wheel structure, grit size, and speed. Finer grits give a smoother surface. Coarse grits remove more material but leave a rougher finish. Resin bonds work well with fine grits for a smooth finish. Vitrified bonds give you a strong wheel for precise work. Faster wheel speeds can help your finish by stopping wheel loading. Always use coolant to lower heat and friction. This helps your wheel last longer and improves finish quality. You need to balance grit size and structure to match your finish goals. Cbn grinding wheels help you get the best finish, especially in high precision and big jobs. You get steady results and a surface that meets your standards.
Note: The right mix of structure, grit, and bond type lets you control your finish and grinding performance.
Grinding Wheel Structure and Application Comparison Table
Material/Application | Recommended Wheel Structure | Abrasive Type | Best For | Key Features/Performance |
|---|---|---|---|---|
Aluminum | Open/Medium | Silicon Carbide + Aluminum Oxide | High cut rate, non-loading | Fast chip clearance, cool grinding |
Stainless Steel | Medium/Dense | Ceramic Alumina, White Aluminum Oxide | Precision, long life | Low heat, high finish quality |
Carbon/Structural Steel | Medium | Ceramic Alumina, Zirconia Alumina, Aluminum Oxide | Versatile, cool cutting | Self-sharpening, consistent performance |
Cast Iron | Medium/Open | Silicon Carbide | Aggressive cut, low heat | Reduces thermal damage, smooth finish |
Ceramics/Glass | Dense/Structured | Resin-bonded Diamond | High precision, minimal chipping | Micro/macro-textures, reduced grinding force |
Tool Steels (Hard) | Dense/Medium | CBN | High precision, long life | Maintains shape, top surface finish quality |
Trade-Offs: Open vs. Dense Structures
Open structures clear chips better and keep things cooler. You remove material faster and lower the risk of burning the surface. These work best for roughing and soft materials.
Dense structures pack more abrasive grains together. You get a finer finish and higher accuracy. These can trap heat, so you must use coolant. They work best for hard, brittle materials and high precision jobs.
Remember: Always pick your grinding wheel structure based on your material, job, and finish goals. This helps you get the best performance and surface finish every time.
When to Use Each Structure
Open Structure Uses
Pick open structure wheels for rough grinding jobs. These wheels have fewer abrasive grains. This lets more coolant move through the wheel. Your workpiece stays cool and does not burn. Open structure wheels are best when you need to remove lots of material fast. They work well with cbn for tough grinding. You often use them in cylindrical grinding. This is when you shape round things like rollers and shafts. Centerless grinding also uses open structure wheels. These wheels handle rods, bearings, and tubes. These jobs need fast chip removal and steady work. Open structure wheels help keep your area clean. They also keep your cbn wheel sharp. You get better results and longer wheel life with these wheels.
You use open structure wheels for:
Rough grinding that removes a lot of material
Cylindrical grinding for rollers and shafts
Centerless grinding for rods, bearings, and tubes
Grinding soft metals or things that clog dense wheels
Tip: Use open structure wheels with cbn for fast and cool grinding in hard jobs.
Medium Structure Uses
Medium structure wheels give balanced grinding for many jobs. Use them for general grinding on ferrous metals like steel and welds. These wheels are good when you want both speed and long life. Medium structure wheels work for heavy jobs like weld removal and rust cleaning. They also help with deburring. You get good coolant flow and chip removal. This helps your cbn wheel last longer. In metal shops, medium structure wheels remove heavy stock and keep grinding steady. You can trust these wheels for jobs that need both strong cutting and durability.
Note: Medium structure wheels are great when you want both fast grinding and strong performance with cbn.
Dense Structure Uses
Dense structure wheels are best for precision grinding. Use them when you need a smooth finish and high accuracy. Dense wheels have more abrasive grains packed together. This gives you a smoother surface. These wheels are best for tool making and grinding hard or brittle materials. They also work well for finishing with cbn. You often use dense wheels for grinding ceramics, glass, or tool steels. These jobs need careful heat control, so always use coolant. Dense wheels help you reach your finish goals and keep your cbn wheel in shape. You get the best results when surface quality is most important.
Pick dense structure wheels for:
Precision grinding of hard or brittle materials
Jobs that need a mirror-like finish
Tool making and finishing with cbn
Grinding ceramics, glass, and tool steels
Remember: Dense structure wheels give you the best results in high-precision jobs with cbn.
Key Factors
Material Hardness
You should think about how hard your workpiece is before picking a grinding wheel. Hard materials need a different wheel than soft ones. For hard materials, use a closed structure. This helps you get high precision and keeps grains sharp. Closed structures stop glazing and protect the cbn wheel. For soft materials, pick an open structure. This gives better chip clearance and makes grinding faster. You can remove more material and your cbn wheel lasts longer. The table below shows how hardness changes your grinding wheel choice:
Workpiece Material Hardness | Recommended Grit Size | Recommended Wheel Grade | Wheel Structure (Spacing) | Explanation |
|---|---|---|---|---|
Hard Materials | Fine | Soft | Closed (less space) | Fine grit cuts better; soft grade lets grains break away for new sharp points; closed structure helps get a smooth finish and stops glazing. |
Soft Materials | Coarse | Hard | Open (more space) | Coarse grit removes material fast; hard grade keeps grains longer for wheel life; open structure clears chips and helps remove more material. |
Heat Sensitivity
Some materials get damaged by heat when grinding. You should use wet grinding to keep things cool. Coolant stops burning and keeps the cbn wheel working well. Open structure wheels are best for these jobs. They let chips out and lower heat. Softer wheels also help protect the surface and keep quality high. Resin-bonded cbn wheels are more flexible and shake less. This helps you grind with more accuracy and keeps results good. Always pick a wheel that matches how much heat your material can take.
Removal Rate
If you want to take off a lot of material fast, use a grinding wheel with lots of pores. Open structures let more coolant and chips move through. This lowers grinding force and keeps your cbn wheel sharp. In busy factories, you get better results and your tools last longer. You also do not need to dress the wheel as much. Taking deeper cuts helps you remove more and keeps your finish steady. Open structure wheels are great for fast and strong grinding.
Machine Power
Your machine’s power decides which grinding wheel you can use. Strong machines can use dense structure wheels for careful work. Weaker machines do better with open structure wheels. These wheels need less force and help your cbn wheel last longer. Always check your machine before picking a wheel. The right wheel gives you better grinding, higher speed, and a good finish. You get steady results and your cbn wheel works longer.
Common Mistakes
Wrong Structure Choice
You can make mistakes when picking a grinding wheel for cbn or other jobs. One common error is choosing the wrong structure. If you use a wheel with grit that is too coarse, your grinding finish will look rough. You might also see scratches on your work. Always match the wheel to your material and finish needs. For a smooth finish, pick a finer grit and sharp abrasive grains. When you use cbn wheels, check the structure and grit size before you start grinding. If you dress your wheel too often, you waste time and wear out your tools. Use rotary diamond dressers for cbn wheels in busy shops. This keeps your grinding sharp and saves money.
Tip: Always check your grinding wheel before use. Look for cracks or damage. Use the ring test to make sure the wheel is safe.
Ignoring Heat
Heat can ruin your grinding job. If you pick a cbn wheel with the wrong structure, you may see too much heat. Wheels that are too dense or have the wrong bond trap chips. This causes friction and raises the temperature. When you grind with cbn, always use enough coolant. Coolant helps keep the grinding area cool and stops burning. If you use a wheel with low porosity, coolant cannot reach the work. This makes heat build up fast. Dress your cbn wheel the right way to keep contact even and control heat. The right grinding wheel structure helps you avoid heat problems and keeps your finish smooth.
Overlooking Machine Limits
You must know your machine’s limits before grinding with cbn wheels. If you run a grinding wheel too fast, you risk a serious safety problem. The wheel can crack or even shatter. Centrifugal force grows quickly as speed increases. Even a small jump in speed can double the force on your cbn wheel. Always follow safety guidelines and never go over the wheel’s rated speed. Check your machine’s power and speed before you start grinding. Use the right cbn wheel for your machine’s strength. This keeps you safe and helps your grinding stay steady.
Practical Tips to Avoid Mistakes
Inspect cbn and other grinding wheels for cracks before use.
Mount wheels with the correct flanges and torque.
Use wheel guards for extra safety.
Dress cbn wheels regularly, but not too often.
Follow all safety guidelines and wear safety gear.
Use coolant to control heat during grinding.
Store cbn wheels in a dry, safe place.
Test new cbn wheels on a small job before full use.
Ask suppliers or experts for help if you are unsure.
Note: Testing your cbn grinding wheels and talking to suppliers helps you get the best results. Experts can help you pick the right wheel for your grinding job and machine.
You get better grinding results when you pick the right structure for your grinding wheel and match it to your material and job. The right cbn wheel and structure help you work safer and make your work look better. Studies show that the right wheel structure makes grinding easier, keeps things cooler, and helps you finish faster. You also keep your work safe and your tools last longer. Always look at the guide and table to help you choose. If you are not sure, ask someone who knows more. Remember, being safe with abrasive wheels starts with picking the right one. Choose the best cbn wheel for good quality, safety, and strong grinding.
FAQ
What does the structure number on a grinding wheel mean?
The structure number shows how tightly the grains pack together. A low number means a dense wheel. A high number means an open wheel. You can use this number to pick the right wheel for your job.
Can I use the same grinding wheel for all materials?
No, you should not use one wheel for every material. Each material needs a different abrasive and structure. You get better results and longer tool life when you match the wheel to the material.
How do I know if I need an open or dense structure?
If you want fast material removal and cooler grinding, choose an open structure. For a smooth finish and high precision, pick a dense structure. Think about your finish goals and the material you work with.
Why does my grinding wheel burn the workpiece?
Your wheel may burn the workpiece if it is too dense or if you use little coolant. You can fix this by using an open structure wheel, increasing coolant flow, or lowering grinding speed.
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