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Tuesday 20 November 2012

Cutting metal in the home shop

he wheels are generally made from a matrix of coarse particles pressed and bonded together to form a solid, circular shape, various profiles and cross sections are available depending on the intended usage for the wheel. They may also be made from a solid steel or aluminium disc with particles bonded to the surface. The manufacture of these wheels is a precise and tightly controlled process, due not only to the inherent safety risks of a spinning disc, but also the composition and uniformity required to prevent that disc from exploding due to the high stresses produced on rotation

Grain size, from 8 (coarsest) 1200 (finest), determines the physical size of the abrasive grains in the wheel. A larger grain will cut freely, allowing fast cutting but poor surface finish. Ultra-fine grain sizes are for precision finish work.
Wheel grade, from A (soft) to Z (hard), determines how tightly the bond holds the abrasive. Grade affects almost all considerations of grinding, such as wheel speed, coolant flow, maximum and minimum feed rates, and grinding depth.
Grain spacing, or structure, from 1 (densest) to 16 (least dense). Density is the ratio of bond and abrasive to air space. A less-dense wheel will cut freely, and has a large effect on surface finish. It is also able to take a deeper or wider cut with less coolant, as the chip clearance on the wheel is greater.
Wheel bond, how the wheel holds the abrasives, affects finish, coolant, and minimum/maximum wheel speed.
  • Vitrified (V)
  • Resinoid (B)
  • Silicate (S)
  • Shellac (E)
  • Rubber (R)
  • Metal (M)
  • Oxychloride (O)

Tapered wheel

A straight wheel that tapers outward towards the center of the wheel. This arrangement is stronger than straight wheels and can accept higher lateral loads. Tapered face straight wheel is primarily used for grinding thread, gear teeth etc.


Straight cup

Straight cup wheels are an alternative to cup wheels in tool and cutter grinders, where having an additional radial grinding surface is beneficial.


Dish cup

A very shallow cup-style grinding wheel. The thinness allows grinding in slots and crevices. It is used primarily in cutter grinding and jig grinding.

Saucer wheel

A special grinding profile that is used to grind milling cutters and twist drills. It is most common in non-machining areas, as sawfilers use saucer wheels in the maintenance of saw blades