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INTRODUCTION

CONTENT Details Page

BONDS Resin-ceramic 1

cBN in vitrified bond 1

Metal 2

Galvanic surface layer 2

Bakelite 3

Ceramic 3

Grinding agents Diamond and cBN 4

Grit sizes cBN 5

Diamant 6

Comparison micron grit sizes 7

Concentration C (V) 8

Surface quality Rz, Ra 9

Cutting speed m/sec r.p.m. 10

Wheels engraving Haefeli-ID 11

Apr 05

HAEFELI Diamantwerkzeugfabrik AG, CH-8046 ZürichRiedenhaldenstrasse 51 Tel: +41 (0)44 377 80 50 Fax: +41 (0)44 377 80 60 Email: [email protected] Internet: www.haefeli-info.ch

Entwicklung und Fabrikation von

cBN- und Diamantwerkzeugen

BONDS

Resin-ceramic bond (Resin) cBN in vitrified bond (Vitrified)

Haefeli bond name: R100 - R999 Haefeli bond name: V5000 - V5999

Products ProductsType: 1A1, 1V1, 11V9, 12A2, profiles, 1A1W Type: 1A1W, 1A1, profiles

Diameter: ∅ 3.0 - 400 mm Diameter: ∅ 4.0 - 60 mmGranulation: D7 - D251 Granulation: D46 - D251

Concentration: C 30 - C 125 Concentration: C 100 - C 150

Application: Materials for diamond:Hard metal, cermets

Materials for cBN: Application: Materials for cBN:

Cooling: Oil, emulsion, dry Cooling: Only with cooling, such as oil, emulsion

Regeneration: HACO-FLEX manually Regeneration: -Dressing: Dressing: Rotating, metal-bonded conical wheels

Apr 05




In addition to the grit size and concentration, the bond decisively determines the performance and behaviour of the Diamond and

cBN wheel. Various adapted bonds provide optimum solutions for numerous different grinding tasks. They are distinguished based

on their binder materials, which in turn contain numerous alloy types.

Rotating SiC wheels (no stationary tool or

metal-bonded dressing wheels!)

HSS, alloyed tool steel, hardened steel

The mixture of meltable glass powder, filler and cBN

abrasive wheel constitutes the ceramic bond. In contrast to

the resin-ceramic and metal bonds, the vitrified bond offers

a.o. the advantage that a certain pore volume can be

produced. As the bond is made from glass, the grinding

wheels cannot withstand major impacts or temperature

shocks. Cooling is therefore always required. The ceramic

bond provides cool grinding with low grinding forces and

can be easily dressed on the machine, using a rotating

dresser.

Resins, to which apart from the grinding granules also filler

has been added, are used as binding agent. Grinding wheels

with resin-ceramic bond offer a wide range of application.

The wheels offer rapid and cool grinding, can be used for dry

and wet grinding and generate only low grinding forces. The

resin-ceramic bond is used from polishing grinding to deep

grinding processes with high rates of material removal. In

short, it is the most universal bond.

HSS, alloyed tool steel, hardened steel

BONDS

Metal bond: (Metal) Galvanic surface layer: (Electro plated)

Haefeli bond name: M4000 - M4999 Haefeli bond name: E6000 - E6999

Products ProductsType: 1A1W, profiles such as 14E1, 14A1R, Type: 1A1, profiles, 1A1W

Diameter: ∅ 0.2 - 300 mm Diameter: ∅ 0.5 - 400 mmGranulation: D16 - D251 Granulation: D46 - D352

Concentration: C 30 - C 175

Application: Materials for diamond: Application: Materials for diamond:

Materials for cBN: Materials for cBN:

Cooling: Oil, emulsion Cooling: Oil, emulsion, dry

Regeneration: HACO-FLEX manually Regeneration: -Dressing: Dressing: -

Apr 05




This bond is electro-plated onto a steel base structure. As a

result of this single-layer bonding process, the grinding

coating produces large swarfs. The galvanic bond is

particularly suited for applying to profiled base structures.

Profile accuracy does, however, depend on the grain size.

Due to the large grain overhang, the covered workpiece

offers a very good grip and leaves the workpiece with a

very rough surface. With increased use, the grip is reduced

as the grain peaks are worn away.

Rotating SiC wheels (no stationary tool or

metal-bonded dressing wheels!)

Hard metal, cermets, sapphire, ruby, glass,

technical ceramics

HSS, alloyed tool steel, hardened steel HSS, alloyed tool steel, hardened steel

Sintered metal bonds are predominantly bronze bonds and

are characterised by a higher bond hardness. The grains are

tightly enclosed, as a result of which, the grinding wheel

appears to be "more blunt" but offers a significantly longer

service life. In contrast to resin-ceramic-bonded grinding

wheels, the metal bond generates more grinding heat if it is

not regenerated effectively (-> HACO-FLEX). Grinding

wheels with metal bonds achieve harder grinding at a lower

speed. Metal bonding is best suited for sharp profiles from

radius R 0.08 mm onwards, thin bond widths and very small

sintered grinding pins (from Ø 0.2 mm) and for use on

materials subjecting the bond to high levels of wear. Metal

bonds are generally the most hard wearing bonds.

Hard metal, plastic, glass fiber reinforced

plastic

BONDS

Bakelite bond (Bakelite) Ceramic bond

Haefeli bond name: B3000 - B3999

Apr 05


Bakelite, to which apart from the grinding granules also filler

has been added, is used as binding agent. In the past, the

bonding was used with fine granules due to its polishing

effect. Grinding wheels with bakelite bond are only still used

in a few exceptional cases as bakelite can be substituted by

more versatile and more cleanly cutting resin bonds.

The ceramic bond consists of meltable glass powder, filler

and abrasive grains. It is the cheapest and most popular

bond. It can also be used to grind "soft" (

SCHLEIFMITTEL

- Hartmetall - carbur de tungstene - tungsten carbide - Keramik - céramique - ceramic - Glas - verre - glass - Saphir - saphire - saphire - Graphit - graphite - graphite - Ferrit - ferrite - ferrite - Ferro-Tic - ferro-tic - ferro-tic - u.s.w. - e.t.c. - a.s.f.

- HSS-Stähle - acier HSS - high-speed steel - Werkzeugstähle - acier à outils et étampage - tool and die steel - Einsatz-Stähle - acier de cémentation - carburized steel - Stellit - stéllite - stellite - u.s.w. - e.t.c. - a.s.f.

Material: Knoop Härte: Matière: Knoop dureté: Material: Knoop hardness:Diamant 8000 Diamant 8000 Diamond 8000cBN 4500 cBN 4500 cBN 4500SiC 2700 SiC 2700 SiC 2700

Al203 2500 Al 2 0 3 2500 Al203 2500

Apr 05




LES MATIÈRES ABRASIVESDIAMANTLe Diamant est la matière la plus

dur (8000 dureté Knoop) qu'on

connaît et convient au meulage

des matières dont au moins une

partie est cristaline, soit:

DIAMANTDiamant ist das härteste bekannte

Material (8000 Knoop Härte) und

eignet sich zum Schleifen von

kristallinen Werkstoffen wie:

cBN ( c ubic B oron N itride ) (Borazon)Le cBN et la matière la plus dure

après le Diamant (4500 dureté

Knoop) qu'on conna'it et convient

au meulage des matières sans

partie cristaline, soit:

Les matières les plus dures en

comparaison:

cBN (cubic Boron Nitride) (Borazon)cBN ist das zweithärteste Material

(4500 Knoop Härte) und eignet sich

zum Schleifen von Werkstoffen

ohne kristalline Anteile wie:

Die härtesten Materialien im

Vergleich:

The hardest materials in

comparison:

GRINDING AGENTS

DIAMONDDiamond is the hardest material

known (8000 Knoop hardness) and

is suited for grinding of material

with at least part of crystaline

content, such as:

cBN is the second hardest material

known (4500 Knoop hardness) and

is suited for grinding material

without crystalline content such

as:

cBN (cubic Boron Nitride) (Borazon)

cBN KORNGRÖSSEN / DIMENSIONS DES GRAINS / GRIT SIZES

For cBN grinding tools cBN

Application US mesh Micron

min.

Micron

max. FEPA

212 250 +1= BN 251 Very rough ginding = 60 - 70 180 212 +1= BN 213 = 70 - 80 150 180 +1= BN 181 = 80 - 100 125 150 +1= BN 151 = 100 - 120 106 125 +1= BN 126 = 120 - 140 90 106 +1= BN 107 Rough grinding = 140 - 170 75 90 +1= BN 91 = 170 - 200 63 75 +1= BN 76 = 200 - 230 53 63 +1= BN 64 Semifinish grinding = 230 - 270 45 53 +1= BN 54 = 270 - 325 38 45 +1= BN 46 = 325 - 400

Micron-Grit sizes Micron

min.

Micron

max. HAEFELI30 40 +1= BN 41 MB 40 Fine grinding32 38 +1= BN 39 B 35 = 400 - 500 22 36 +1= BN 37 B 30 25 32 +1= BN 33 B 30 Ultrafine grinding = 500 - 600 20 30 +1= BN 31 MB 2510 20 +1= BN 21 MB 168 15 +1= BN 16 MB 15 (abt. 1000 ) 6 12 +1= BN 13 MB 10

US mesh

(US mesh): Grains per inch

1" = 25,4 mm

max. Grit size FEPA .

ø

180 micr. + 1 micr. = BN 181 80 - 100 = 80-100 Grains per inch 180/1000 mm

45 micr. + 1 micr. = BN 46 325 - 400 = 325-400 Grains per inch 45/1000 mm

HAEFELI-Micron-Grit sizes follow the logic of FEPA-norm (biggest grit in micron + 1 = FEPA/HAEFELI-norm)

Dez 05


Ceramic wheels

(SiC, Al203, ..)

FEPA-Grit sizes

Other

producers

description



DIAMOND KORNGRÖSSEN / DIMENSIONS DES GRAINS / GRIT SIZES

For diamond grinding tools DIAMOND

Application US mesh Micron

min.

Micron

max. FEPA

212 250 +1= D 251 = 60 - 70 180 212 +1= D 213 = 70 - 80 150 180 +1= D 181 Rough grinding = 80 - 100 125 150 +1= D 151 = 100 - 120 106 125 +1= D 126 = 120 - 140 90 106 +1= D 107 Semifinish grinding = 140 - 170 75 90 +1= D 91 = 170 - 200 63 75 +1= D 76 = 200 - 230 53 63 +1= D 64 Fine grinding = 230 - 270 45 53 +1= D 54 = 270 - 325 38 45 +1= D 46 = 325 - 400

Micron-Grit sizes Micron

min.

Micron

max. HAEFELI30 40 +1= D 41 MD 40 Ultrafine grinding32 38 +1= D 39 D 35 = 400 - 500 22 36 +1= D 37 D 30 25 32 +1= D 33 D 30 = 500 - 600 20 30 +1= D 31 MD 2515 25 +1= D 2610 20 +1= D 21 MD 168 15 +1= D 16 MD 15 (abt. 1000 ) 6 12 +1= D 13 MD 10

US mesh

(US mesh): Grains per inch

1" = 25,4 mm

max. Grit size FEPA .

ø

180 micr. + 1 micr. = D 181 80 - 100 = 80-100 Grains per inch 180/1000 mm

45 micr. + 1 micr. = D 46 325 - 400 = 325-400 Grains per inch 45/1000 mm

HAEFELI-Micron-Grit sizes follow the logic of FEPA-norm (biggest grit in micron + 1 = FEPA/HAEFELI-norm)

Dez 05


Ceramic wheels

(SiC, Al203, ..)

FEPA-Grit sizes

Other

producers

description



Micron

min.

Micron

max +1=

32 52 D 25

30 45 MD 40 / MB 40

32 40 D 35

30 40 +1= MD / MB 42 D 20 B / B 3020 40 +1= MD / MB 41 MD 25 / MB 2532 38 +1= MD / MB 3922 36 +1= MD / MB 3725 32 +1= MD / MB 33 D 30 / B 3025 30 D 20 A / B 30

20 30 +1= MD / MB 31 D 25 MD 2020 25 D 15 C

15 25 +1= MD / MB 26 D 20 MD 18 D 30 / B 3010 25 D 15

12 22 +1= MD / MB 23 MD 16 / MB 1615 20 D 15 B / B 15 D 20

10 20 +1= MD / MB 21 D 15 / B 15 D 15 / B 1510 16 MD 14

8 / 10 15 +1= MD / MB 16 D 10 D 15 A / B 96 12 +1= MD / MB 13 D 7 MD 10 D 10 / B 106 10 +1= MD / MB 115 10 D 7 / B 6

4 8 +1= MD / MB 9 D 6 MD 6.3 D 63 6 +1= MD 7 MD 42 5 D 3 / B 3

1 5 +1= MD 62 4 +1= MD 5 D 3 MD 2.52 3 MD 1.8

0.5 3 +1= MD 41 2 +1= MD 3 D 1 D 1 / B 1 MD 10 1 +1= MD 20.5 1 D 0.7

< 0.5 D 0.25

Dez 05




Vergleich Micron - Korngrössen / Comparaison des grains microns / Comparison micron grit sizes

Micron-Körnungen nach FEPA Idee

Grains micron d'après idée FEPA micron grit sizes following FEPA idea

Bezeichnung

Hersteller D

Désignation

producteur D Descprition

producer DHAEFELI

Bezeichnung

Hersteller A

Désignation

producteur A Descprition

producer A

Bezeichnung

Hersteller B

Désignation

producteur B Descprition

producer B

Bezeichnung

Hersteller C

Désignation

producteur C Descprition

producer C



cBN KONZENTRATION / CONCENTRATION CDIAMANT

Konzentration C: cBN/Diamant-Körner Sättigung im SchleifbelagConcentration C: Densité des grain cBN/Diamant dans le liantConcentration C: Density of the cB/Diamond grit in the bond

Ansicht Volumen Fepa

vue cBN + Diamant cBN + Diamant cBNview % C V

0 V% C 0 (V0)

7.5 V% C 30 V70

12.5 V% C 50 V120

15 V% C 60 V150

18.75 V% C 75 V180

25 V% C 100 V240

31.25 V% C 125 V300

37.5 V% C 150 V360

50 V% C 200 V480

100 V% C 400 (V1000)

Apr 05


Bezeichnung / Désignation /

DesignationSchleifbelag / Couche / Layer

OBERFLÄCHENGÜTE / L'ETAT DE SURFACE / SURFACE QUALITY

Kreuzschliff - Richtwerte / Meulage croisée - Valeurs indicatives / Cross grinding - Standard values

Ra (micr.)

Rmax (micr.)

Rz (micr.)

cBN DIAMOND

BN 151

BN 126

BN 107 D 181

BN 91 D 151

BN 76 D 126

BN 64 D 107

BN 54 D 91

BN 46 D 76

D 64

D 54

D 46

D 41

D 26

D 13

Feinstschleifen Feinschleifen Vorschleifen Grobschleifen Schruppen

Superfinition Finition Ebauche Ebauche grossière Dégrossissage

Ultrafine grinding Fine grinding Semifinish grinding Rough grinding Very rough grinding

Dez 05


Fine grinding

Finition

Feinschleifen

Ultrafine grinding

Superfinition

Feinstschleifen



0.4

5.0

4.0

0.05

0.80

0.63

0.025

0.50

0.40

Ebauche

2.0

N 5

1.25

1.00

N 4

Rough grinding

Ebauche grossière

Grobschleifen

Vorschleifen

N 6N 2N 1 N 3

0.10 0.2

2.5

Schleifen mit HAEFELI Kunstharz-Keramik-Bindungen / Meulage avec des liants HAEFELI résine-céramique / Grinding with HAEFELI resin ceramic bonds

Schruppen

Very rough grinding

Semifinish grinding

6.3

8.0

0.8

2 5 10 15 20 25 30 35 40 45(m/sec) (m/sec) (m/sec) (m/sec) (m/sec) (m/sec) (m/sec) (m/sec) (m/sec) (m/sec)

r.p.m.

∅ 600 mm `64 `159 `318 `477 `637 `796 `955 1`114 1`273 1`432 r.p.m.∅ 500 mm `76 `191 `382 `573 `764 `955 1`146 1`337 1`528 1`719 r.p.m.∅ 400 mm `95 `239 `477 `716 `955 1`194 1`432 1`671 1`910 2`148 r.p.m.∅ 350 mm `109 `273 `546 `818 1`091 1`364 1`637 1`910 2`182 2`455 r.p.m.∅ 300 mm `127 `318 `637 `955 1`273 1`591 1`910 2`228 2`546 2`864 r.p.m.∅ 250 mm `153 `382 `764 1`146 1`528 1`910 2`292 2`673 3`055 3`437 r.p.m.∅ 225 mm `170 `424 `849 1`273 1`697 2`122 2`546 2`971 3`395 3`819 r.p.m.∅ 200 mm `191 `477 `955 1`432 1`910 2`387 2`864 3`342 3`819 4`297 r.p.m.∅ 175 mm `218 `546 1`091 1`637 2`182 2`728 3`274 3`819 4`365 4`910 r.p.m.∅ 150 mm `255 `637 1`273 1`910 2`546 3`183 3`819 4`456 5`092 5`729 r.p.m.∅ 125 mm `306 `764 1`528 2`292 3`055 3`819 4`583 5`347 6`111 6`875 r.p.m.∅ 100 mm `382 `955 1`910 2`864 3`819 4`774 5`729 6`684 7`638 8`593 r.p.m.∅ 75 mm `509 1`273 2`546 3`819 5`092 6`365 7`638 8`912 10`185 11`458 r.p.m.∅ 50 mm `764 1`910 3`819 5`729 7`638 9`548 11`458 13`367 15`277 17`187 r.p.m.∅ 40 mm `955 2`387 4`774 7`161 9`548 11`935 14`322 16`709 19`096 21`483 r.p.m.∅ 30 mm 1`273 3`183 6`365 9`548 12`731 15`913 19`096 22`279 25`461 28`644 r.p.m.∅ 25 mm 1`528 3`819 7`638 11`458 15`277 19`096 22`915 26`735 30`554 34`373 r.p.m.∅ 20 mm 1`910 4`774 9`548 14`322 19`096 23`870 28`644 33`418 38`192 42`966 r.p.m.∅ 15 mm 2`546 6`365 12`731 19`096 25`461 31`827 38`192 44`558 50`923 57`288 r.p.m.∅ 12 mm 3`183 7`957 15`913 23`870 31`827 39`784 47`740 55`697 63`654 71`610 r.p.m.∅ 10 mm 3`819 9`548 19`096 28`644 38`192 47`740 57`288 66`836 76`384 85`933 r.p.m.∅ 8 mm 4`774 11`935 23`870 35`805 47`740 59`675 71`610 83`546 95`481 107`416 r.p.m.∅ 6 mm 6`365 15`913 31`827 47`740 63`654 79`567 95`481 111`394 127`307 143`221 r.p.m.∅ 5 mm 7`638 19`096 38`192 57`288 76`384 95`481 114`577 133`673 152`769 171`865 r.p.m.∅ 4 mm 9`548 23`870 47`740 71`610 95`481 119`351 143`221 167`091 190`961 214`831 r.p.m.∅ 3 mm 12`731 31`827 63`654 95`481 127`307 159`134 190`961 222`788 254`615 286`442 r.p.m.∅ 2 mm 19`096 47`740 95`481 143`221 190`961 238`701 286`442 334`182 r.p.m.∅ 1.8 mm 21`218 53`045 106`090 159`134 212`179 265`224 318`269 r.p.m.∅ 1.5 mm 25`461 63`654 127`307 190`961 254`615 318`269 r.p.m.∅ 1.2 mm 31`827 79`567 159`134 238`701 318`269 r.p.m.∅ 1.0 mm 38`192 95`481 190`961 286`442 r.p.m.∅ 0.8 mm 47`740 119`351 238`701 r.p.m.∅ 0.6 mm 63`654 159`134 318`269 r.p.m.∅ 0.5 mm 76`384 190`961 r.p.m.∅ 0.4 mm 95`481 238`701 r.p.m.∅ 0.3 mm 127`307 318`269 r.p.m.∅ 0.2 mm 190`961 r.p.m.




Apr 05

cBN- und Diamantwerkzeuge / outils cBN et Diamant / cBN and Diamond tools

SCHNITT-GESCHWINDIGKEIT / VITESSE DE COUPE / CUTTING SPEED

Schleifkörper-

Durchmesser

Diamètre de la

meule

Diameter of the

wheel

Vollkeramik / vitrifiée / vitrified

Metall / métal / metal

Kunstharz-Keramik / résine-céramique / resin-ceramic

r.p.m.

BindungLiantBond

ProduktionsnummerNo. de productionsProductionnumber

KonzentrationConcentration

cBN oder DiamantKorngrösse cBN ou DiamantGrain cBN or DiamantGrit size

Apr 05


SCHEIBEN-GRAVUR / GRAVAGE DE MEULES / WHEELS ENGRAVING



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