Whether dressing a wheel OPEN or CLOSED you can count on Fliesen tools. Open wheels (sharp, free-cutting abrasive grains are exposed) are created by increasing the speed a Fliesen tool moves across the wheel when dressing. Generally considered the most favorable wheel conditioning, open wheels avoid workpiece burn while maximizing a wheel’s ability to remove metal quickly when grinding.
Slowing a Fliesen tool as it moves across the wheel creates a closed wheel condition (abrasive grains are smoother, less sharp), a very helpful condition when trying to lower part surface finish readings.
You can count on Fliesen stationary diamond dressing tools. Open wheels (sharp, free-cutting abrasive grains are exposed) are created by increasing the speed a tool moves across the wheel. Open wheels maximize a wheel’s ability to remove metal quickly when grinding. Slowing a tool as it moves across the wheel creates a closed wheel (abrasive grains are smoother, less sharp), which is ideal when trying to lower part surface finish readings.
Are you dressing modern ceramic alumina grinding wheels? Our new Furioso plates and shank tools are made of the new generation of highly wear-resistant diamond blades, engineered to stand up to durable modern ceramic alumina grinding wheels, including Norton Quantum wheels. (see Furioso flyer in “Related Documents”.)
Norton No-Risk Test Policy
There is no better time to improve productivity in your abrasive operations. Saint-Gobain’s new No-Risk Productivity Policy is designed to help you improve any of your production goals including improved cycle times, lower total production costs, higher quality parts, or improved finish, while eliminating any risk. You define the metrics that determine a successful test as well as what is necessary to eliminate any risks, and our technical salesperson will identify the right product to help you meet your production needs, no matter what competive product you are currently using.
WHAT DOES NO RISK MEAN?
- You have absolutely nothing to lose and everything to gain.
- You define the application requirements and the metrics of a successful test.
- You define the definition of No-Risk in terms of cost to test, downtime, part rejection, and any other risk that is important to you.
- You define the time period of the test.
The Benefits of Fliesen Tools
Spend More Time Grinding
Single point, chisel, and cone point tools require operator attention to ensure proper tool rotation at regular intervals. Fliesen tools require no adjustments. Simply install the tool, dress the wheel to break it in, and the tool will do the rest. Operators spend more time grinding – rather than making non-productive dressing adjustments.
Longer Tool Life
Expect long life when using a Fliesen tool. Other stationary tools, made with a single diamond stone, develop flat spots (“wear flats”) over time – which create chatter and burn. Fliesen tools use hand-set, fine diamond grit, eliminating the creation of wear flats.
Reliable and Cost-Effective
Harder, H-bond metal formulation Fliesen tools have been specifically engineered to efficiently dress durable silicon carbide and ceramic wheels. Our new Furioso Fliesen tools have a unique bond system developed for optimal performance when dressing Quantum (NQ) ceramic wheels. W-bond Fliesen tools are designed for conventional aluminum oxide wheels.
Fliesen Tool Configurations
Fliesen tools are available in two basic tool configurations. The most common is a plate configuration, which is somewhat rectangular-shaped with a mounting hole. Fliesen Shank Tool configurations are plates mounted in shanks of varying sizes and shapes. Most grinding machines accommodate one or the other tool configuration. To find the correct tool configuration for your machine, check the existing dressing tool, refer to the Tools by Machine Type Index in this catalog, or consult your grinding machine manual.
MATCH THE CORRECT FLIESEN TOOL TO YOUR GRINDING WHEEL ABRASIVE
Use Fliesen tools with W-bond specifications for aluminum oxide wheels. W-bonded tools have the standard matrix of metal surrounding the diamonds. When dressing more durable abrasive wheels, such as silicon carbide and ceramic, use our H-bonded tools, or our new Furioso tools for Quantum and other ceramic wheels, which are harder and more durable. Markings on the tool indicate the tool’s bond matrix. Use the right bond matrix for your abrasive application, as each is specifically engineered to perform best on the abrasive it was designed for. The catalog product charts are categorized by abrasive and appropriate bond.
FLIESEN TOOL MOUNTING GUIDELINES
1. Be sure to mount the tool correctly. Tool contact surface should be perpendicular to wheel.
2. Mount tool with diamond on trailing edge whenever possible as shown below.
RECOMMENDED DRESSING PARAMETERS
There are three elements to proper dressing. Dresser Infeed is the amount of material the tool takes off per dress pass. Dress Traverse Rate is the speed at which the tool moves across the wheel. The third element is the Number of Passes across the wheel. We recommend the following:
1. Dresser Infeed
Dresser Infeed (amount tool moves into wheel) = .0005″ to .0015″ (.012mm – .038mm) for aluminum oxide wheels. Reduce by 25% when dressing silicon carbide or ceramic wheels.
2. Dress Traverse Rate
Select a Lead Value based on desired Surface Finish and run the formula below.
FINISH LEAD VALUE (PER WHEEL REVOLUTIONS)
For Coarse Finish (approx. 64 rms) .023″ to .030″ (.58mm – .76mm)
For Medium Finish (approx. 32 rms) .013″ to .022″ (.33mm – .57mm)
For Fine Finish (approx 16 rms) .006″ to .012″ (.15mm – .33mm)
DRESS TRAVERSE FORMULA:
Lead Value x Wheel Speed (RPM) = Inches/Minutes (mm/Min)
3. Number of Passes
One is required. Take more as needed to restore form or finish. Dress passes should always remove material from the wheel. If your tool is not cutting the wheel, it is dulling the wheel. Avoid dry or dead dress passes which do not remove wheel material.
MAXIMIZING TOOL LIFE AND EFFECTIVENESS
The goal of dressing is to maximize the wheel’s sharpness – for maximum metal removal when grinding. This is best accomplished through disciplined dressing speeds and feeds. Taking too much off per dress pass, and/or moving the tool too slowly across the wheel will cause the Fliesen tool to overheat, breakdown and wear prematurely. To maximize the tool’s effectiveness, increase the dress traverse rate as high as possible while maintaining part print surface finish requirements.
The diamonds in new Fliesen tools are often covered by the metal surrounding them and should undergo a break-in process before production dressing. This process ensures that the effective diamond layer is properly exposed. This is achieved by taking 3 – 5 dress passes at .005″ depth of cut (on wheel radius) at normal dress traverse rates.
Because the diamonds are set at a slight angle, it is normal for some diamonds to remain buried in the metal after the break-in and during production dressing.
Fliesen tools should be used with coolant whenever possible, to avoid overheating and shortening tool life. We recommend at least a .50″ (12.7mm) diameter stream of steady coolant be positioned so that the air barrier surrounding the wheel “pulls” the coolant (through the dressing action). A coolant velocity of 3% to 5% faster than the wheel’s surface feet per minute works well, or enough pressure to penetrate the air barrier surrounding the wheel as it spins.
RADIUS DRESSING CAPABILITIES
For most angle-head truing and dressing applications, Fliesen tools can provide uniform and consistent radius-generation second only to chisel and cone point type tools. When dressing very intricate forms, tool selection should be driven by the smallest concave or fillet radius needed to generate the desired radii, rather than wheel grit size. Refer to the chart below for radius dressing capabilities by diamond size.