High Performance

Grinding Solutions

SAK ABRASIVES LIMITED

SAK ABRASIVES LIMITED
Sak Abrasives Limited started in 1997 with the objective of supplying Indian Industries with
high-performance grinding wheels at affordable prices. At that time the growing Indian market
was supplied by very few companies and the trend towards precision-engineered products
left a void that we were quick to fill. In collaboration with the Swiss company,
Rastawerk – Switzerland A.G, we started our range with basic resin bonded DC and
cut off wheels made out of a plant in Chennai, India.

Since then there has been no looking back as we expanded our product line in response to
the evolving need of our customers. Backed by a philosophy of rapid but sustainable change
we developed a full range of resin and vitrified bonded abrasives, coated abrasives and the
latest addition of Super Abrasives. This has been accompanied by continual investment in the
up-gradation and modernization of our plant, paving the road to the future.

TOPLINE
Irrespective of whether you are regrinding or making new tools, we have the diamond or
CBN grinding wheel for you. With the help of our technical partner, Superabrasives INC, USA,
we have worked with a number of OEM's and we understand the machinery demands and the
requirement of grinding wheels. Products like Carbide, Stainless or High-speed steel end mills,
drills, punches, reamers and hole saws require multiple steps in manufacturing and we have
developed bond systems and have qualified exact specifications for each operation. With the
latest technology, we are offering all types of Diamond / CBN wheels that comply with
FEPA standards and that are used on CNC machines such as Walters, Rollomatic, ANCA,
Royces, Wendt, TGT, WIDMA etc. in the following industries / applications:

- Rotary Tools
- Cutting Tool Industries
- Wood Working Tools
- Tool Resharpening / Restoring
- Optical Profile Grinding

Let the sparks fly...

Usage of Diamond and CBN wheels
In general, Diamond is used to grind Non- ferrous material as it reacts
with iron. On the other hand, CBN is used to grind Ferrous material.

DIAMOND (D) CBN (CB)

Solid Carbide High Speed Steel
Oxide Ceramics Tool Steel
Glass Heat Treated Steel
Stone Chromium Steel
Procelain, Stone Ware Case Hardened Steel
Semi-conductors Super Alloys
Ferrite Bearing Steel
Stellite- hard facing Stainless Steel
Cast Iron Inconel
GRIT SIZE
USA FEPA
APPLICATIONS WHEEL SHAPE
20/30 D852 COARSER
Fluting 1A1,1V1,1F1 30/40 D602
Primary and secondary relief or end work 11V9 35/40 D501
Gashing 1V1, 12V9 – 30° or 45° 40/50 D427
Grinding top/bottom inserts 6A2 50/60 D301
Grinding peripheral inserts 2A2T 60/80 D252
OD grinding 1A1, 1A1J 80/100 D181
Centerless grinding 1A1, 1A1J 100/120 D151
Surface grinding 1A1 120/140 D126
140/170 D107
170/200 D91
Shape Of Wheels 200/230 D76
1A1 14F1 D
14A1
X X
D 230/270 D64
X
270/325 D54
U

T
T

H
H H 325/400 D46 FINER
=U

J
D J
2R

3A1 6A2 1V1 9A3

W
X

D H W
X
X

X
U

T
T

2A2T
T

T
H
J H
E

VO D
H
D
D D W

6A9 11V9 12V9 1F1

T
X

X
H TH’D.
D D B.C
U

K X
X K
X
U

K
U
T

T
T

700
T
E

0 H
E

45
D
E

H H H
D J J

SAK Wheel Nomenclature

D64 B4 602SW

D: Abrasive Type 2: Concentration S: Sak Abrasives

64: Grit Size
(25-1 ,50-2 , 75-3, W: Wet Grinding
D: Diamond (FEPA Standard
100-4………. Etc) D: Dry Grinding
CB: CBN D64-230/270, 602: Bond Type
D76-200/230 etc) B: Resinoid 601: Carbide, coolant with Oil, Face
64: Finishing
602: Carbide, coolant with Oil & Water, Profiles
126: Roughing
603: Steel, coolant with Oil & Water, profile & slicing
604: Steel, coolant with Oil & Water, ID, Face & Dry Grinding.
605: Carbide & Steel, coolant with Oil & Water, OD, ID,
Plunge, Surface, Centre less for Grit 325 and above
606: Carbide, coolant with water, OD, Plunge, Surface, Centre Less

Sak Abrasives Limited

 PRODUCT IDENTIFICATION

ANSI Wheel Shape Identification System

11 B 9
1 Choose basic core shape 3 Select location of abrasive section
2 Choose shape of abrasive cross section

1. Choose basic core shape

1 2 3 4 6

9 11 12 14 15

2. Abrasive Cross Sections And Marks

A AH B C CH D DD E EE

F FF G H J K L LL

M P Q QQ S

U V Y

3. Location of abrasive section & marks

6. Part of periphery
3. Both Sides

9. Corner

4. Inside Bevel 7. Part of side

1. Periphery or Arc
10. Annular
2. Side

5. Outside Bevel 8. Throughout

Note: Solid black area indicates abrasive placement. or Arc

Sak Abrasives Limited

 TECHNICAL INFORMATION
Technical Guidelines
Avoid Grinding Steel Use Rigid Work Support Coolant – Grind Wet Avoid Excessive Feeds

Avoid steel when grinding with
diamond wheels. Keep the
amount of steel ground to an
absolute minimum.
On brazed tools, use aluminum
oxide wheel to back off the steel
shank.
A high lubricity grinding fluid
should be used.
All workpieces should be Diamond wheels should be Excessive feeds will result in
supported firmly during the used with a full flood coolant premature wheel wear.
grinding process. Any amount of properly directed towards the Excessive feed rates are
vibration will cause wheel wear grinding zone. Water with a rust characterized by:
and produce chatter or wave inhibitor is recommended. - A hard grinding sound
marks on the ground surface. - Chatter
When flood application can’t be
On work ground between used, try mist or spray application. - Burn
- High wheel wear rate
centers, centerholds should be
properly prepared. Use compressed air to - Vibration
“atomize” water or soluble oil.
Minimize work overhang.
Direct the spray at the
If the ground work is supported grinding zone to help
by a work finger, ensure the dissipate heat and prevent
finger is strong enough to heat damage to the work.
provide vibration-free support.

Spec Check
TROUBLESHOOTING GUIDE – DRY GRINDING
PROBLEM POSSIBLE CAUSES SUGGESTED CORRECTION

Burning (excessive heat) Wheel loaded or glazed Dress wheel with a dressing stick
Excessive feed rate Reduce infeed of wheel or workpiece
Wheel too durable Use freer cutting specification or slow down wheel speed
Poor finish Grit size too coarse Select a finer grit size
Excessive feed rate Reduce infeed of wheel or workpiece
Chatter Wheel out of truth True wheel; ensure it is not slipping on mount

TROUBLESHOOTING GUIDE – WET GRINDING

PROBLEM POSSIBLE CAUSES SUGGESTED CORRECTION

Burning (excessive heat) Wheel glazed or loaded Re-dress wheel

Poor coolant placement Apply coolant directly to wheel/workpiece interface
Excessive material removal rate Reduce downfeed and/or crossfeed
Poor finish Excessive dressing Use lighter dressing pressure
Stop dressing as soon as wheel starts to consume stick rapidly
Grit size too coarse Select a finer grit size
Poor coolant flow or location Apply heavy flood so it reaches wheel/work interface
Chatter Wheel out of truth True wheel; ensure it is not slipping on mount
Wheel will not cut Glazed by truing Dress lightly until wheel opens up
Wheel loaded Dress lightly until wheel opens up
Increase coolant flow to keep wheel surface clean
Never run wheel with coolant turned off
Slow cutting Low feeds and speeds Increase feed rate; increase wheel speed
(Do not exceed wheel MOS)
Short wheel life Incorrect coolant flow Apply coolant to flood wheel/work surface
Low wheel speed Increase wheel speed (observe maximum operating speed)
Excessive dressing Use lighter dressing pressure
Wheel too soft or too hard Change grit or grade; use higher concentration

7000

6000
MATERIAL HARDNESS SCALE
Superabrasives is a term used to describe those
Knoop Hardness (H.K.)

5000
abrasives of extreme hardness, which produce
outstanding results when properly used on 4000
specific applications. The following chart provides a
hardness comparison (Knoop Hardness Scale) 3000
between diamond and CBN superabrasives,
2000
aluminum oxide and silicon carbide standard
abrasives, and some common materials these 1000
abrasives are used to grind.
0
e ide ide ve ide sive ide rc s
ond ond asiv Nitr Carb rasi Carb Abra Carb eel H Glas 85
Diam iam BN Abr e Ab d St Hrb
l i ne D C B oron a dium Carbid i licon O xide g sten Har Steel
crys
t a l
talli
n e Va n on
S
inu m Tu n Soft
Poly crys Silic Alum
Poly
RECOMMENDATIONS & GUIDELINES FOR THE SELECTION OF CONCENTRATION IN
RELATION TO GRINDING FORCES
GRINDING AREA OF CONTACT BETWEEN PROFILE & CUTTING EFFICIENCY
FACTORS WHEEL & WORKPIECE BOND EDGE STRENGTH SOFT GRINDING

Large Small Hard Soft

Concentration Low High High Low High Low

Surface Finish
Three factors affect the choice of Abrasive grit:
Quantity of material to be removed
Surface-finish and wheel life
Material removal and wheel life

Surface Finish depends on the adjustment for oscillation-grinding (on pass and in-feed depth) and for
plunge-grinding. A wheel used properly shows a grit penetration depth equal to 1/5-1/8 of the grit dimension.
If the level of roughness needed is known, it is possible to choose the right grit using the following charts:

Permissible Cutting Depth

For Oscillation Grinding
mm
0.04

0.035

0.03
Cutting Depth

0.025

0.02

0.015
Concentration
The Concentration specifies the carats of the
abrasive grain (Diamond or CBN) processed in
0.01
the 1cm3 abrasive layer.
The Concentration influences the performance of the
0.005 Diamond and CBN Grinding tools decisively.
It effects:
The service life of the grinding tool
The stock removal rate
D D D D D D D D D D Profile retention
46 54 64 76 91 107 126 151 181 213 The dimensional constant of the machined work piece.
The finish smoothness of the machined work piece.
FEPA grit size
The price of the grinding tool

Surface Finish Vs Grit Size

Selection Guideline for Grinding of Carbide & Ceramics

181

107

76

54
15
7
(cutting speed approx.: 25m/sec - table speed 15m/min - coolant emulsion)
Ra[µ”] 0,05 0,1 0,2 0,4 0,8 1,6 3,2
AA[µ”] 2 3 8 16 32 64 125
Swiss N2 N3 N4 N5 N6 N7 N8

Sak Abrasives Limited

Expected Surface Finish by Grit Size
Use these charts as guides only. Surface finish is affected by several variables: machine
type and condition, type of material ground, coolant, wheel speed, bond system, etc.

DIAMOND
MAXIMUM DEPTH OF CUT
EXPECTED FINISH EXPECTED FINISH PER PASS FOR GRIT SIZE
GRIT SIZE MICRO INCH AA MICRON Ra INCH MM
100 24 - 32 0.60 - 0.80 0.001” - 0.002” 0.025 - 0.051
120 16 - 18 0.40 - 0.45 0.001” - 0.002” 0.025 - 0.051
150 14 - 16 0.35 - 0.40 0.001” - 0.002” 0.025 - 0.051
180 12 - 14 0.30 - 0.35 0.0007” - 0.001” 0.018 - 0.025
220 10 - 12 0.25 - 0.35 0.0007” - 0.001” 0.018 - 0.025
320 8 0.20 - 0.25 0.0004” - 0.0006” 0.010 - 0.015
400 7-8 0.18 - 0.20 0.0003” - 0.0005” 0.008 - 0.013

CBN
EXPECTED FINISH EXPECTED FINISH EXPECTED FINISH
GRIT SIZE WITH OSCILLATION MICRON Ra PLUNGE
100 35 - 40 0.875 - 1.000 40 - 45
120 30 - 35 0.750 - 0.875 35 - 40
150 25 - 30 0.625 - 0.750 30 - 35
180 20 - 25 0.500 - 0.625 25 - 30
220 15 - 20 0.375 - 0.500 20 - 25
320 10 - 15 0.250 - 0.375 15 - 20
400 4-8 0.100 - 0.200 5 - 10

Recommended Wheel Speeds for Diamond and CBN Wheels

WET GRINDING
CUP WHEELS PERIPHERAL WHEELS

Diamond Grinding Wheels
Resin Bond Wheels
CBN GRINDING WHEELS
Resin Bond Wheels
11V9, 12V9, 15V9, etc.
4921 to 7874 SFPM
25 to 40 m/s
5906 to 9843 SFPM
30 to 50 m/s
1A1, 1V1, 1A1R, etc.
4921 to 7874 SFPM
25 to 40 m/s
5906 to 9843 SFPM
30 to 50 m/s

DRY GRINDING
CUP WHEELS PERIPHERAL WHEELS

Diamond Grinding Wheels
Resin Bond Wheels
CBN GRINDING WHEELS
Resin Bond Wheels
11V9, 12V9, 15V9, etc.
2756 to 3543 SFPM
14 to 18 m/s
2953 to 5906 SFPM
15 to 30 m/s
1A1, 1V1, 1A1R, etc.
2756 to 3543 SFPM
14 to 18 m/s
2953 to 5906 SFPM
15 to 30 m/s

WHEEL SPEED CALCULATION:

To convert m/s to SFPM Multiply M/S x 196.85 = SFPM
To convert SFPM to M/S Divide SFPM by 196.85 = M/S
To convert RPM to SFPM Multiply wheel diameter in inches x RPM x 0.262
M/S = Meters/second
RPM = Revolutions Per Minute
SFPM = Surface Feet Per Minute

Sak Abrasives Limited

 w w w . s a k a b r a s i v e s . c o m

Marketing Office Factory Email US

SP Infocity, 40, MGR Salai, B-49/W, Sipcot Industrial Complex, INDIA
Perungudi, Kandanchavadi, Gummidipoondi - 601 201 super@sakabrasives.com
Chennai - 600 096

Web: www.sakabrasives.com
Phone: 91-44-2454 3500 Phone: 91-44-2792 3104 INTERNATIONAL
Fax: 91-44-2454 3510 Fax: 91-44-2792 3009 exports@sakabrasives.com