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Diamond grinding wheels are known to be extremely durable and cutting. But even these super-abrasive tools cannot be maintained without care to achieve their best. Metal chips, pieces of swarf, and swarf may get stuck in the surface of the wheel, or the diamonds themselves may wear out and become glazed in appearance. This operation is called loading and slows down the cutting process, produces unnecessary heat, and may affect the finish of your work piece. The answer to this is a critical maintenance process known as the dressing.
Learning the Purpose of Dressing
Dressing is not a question of re-molding a wheel that is out of balance or in very bad shape. Rather it has two main purposes in diamond wheels.
The former one is to wipe the wheel. It flattens the particles that are filling the spaces between the diamond particles. This exposes new, sharp crystals of diamonds which would otherwise be covered by a layer of rocks.
The second use is to level off the surface. This assists in forming a flat and smooth grinding surface, and it makes sure that you are in constant contact with your material. The effect is improved accuracy, high quality surface finish, and improved material removal.
Taking Dressing Process Preparations
The first thing is always to be careful. You should also make sure that the grinding machine is totally shut down and has no power connected to it. This eliminates cases of accidental starting up in the process.
Then acquire the dressing equipment. With diamond wheels, the commonly used is the diamond dresser, Includes single-point dresser, multi-point dresser and Diamond Coated Head Wheel Dresser, etc. You should also wear proper personal protective gear such as protective glasses and gloves.
The step-by-step dressing procedure
When you are ready, you can start dressing. These steps are the ones that will give you good and safe results.
Tips on securing the Workpiece and Tool
Clamp the dressing tool firmly in the vise, or holding part, of the machine. It has to be firmly fixed so that it does not move when the operation is being done. The tool must be placed at the same level with the centerline of the wheel.
Executing the Passes
Return power to your grinder. When the wheel is rotating at its normal steady speed, scratch the dressing tool gently across the face of the wheel. Slow and constant cross-feed rate, minimum pressure used. You are aimed to pass on through until you get a nice sharp cutting sound. The implication is that the material that was loaded has been taken off and that new diamonds have been revealed. In most cases, the amount of material that has to be removed is only a few thousandths of an inch.
Post-Dressing checks and Best Practice
When you finish the dressing passes, press the stop button on the machine. Look at the surface of the wheel carefully. It must look clean and granular with no trace of the old glazing or loading.
In order to perform its best, it is advisable to dress the wheel only when one needs it. Wearing an over-dress will make your precious diamond wheel wear and tear unnecessarily and reduce its total life. Never forget to wipe the machine work area after dressing to remove any particles dislodged.
A sharp diamond lap is a useful and efficient tool. Whenever you do your maintenance routine, remember to include the regular dressing, this will mean a smooth operation, better quality finish, and that will give you a good bargain on your investment.