How Copper & Silver Coated Diamonds Boost WC Flute Grinding Life

WC (tungsten carbide) flute grinding is a manufacturing process of extremely hard and wear-resistant material that shapes the grooves or channels for cutting tools to maintain a sharp edge during heavy use. These flutes are essential for chip evacuation during machining and ensure proper chip flow, better surface finish and overall tool performance. However, WC flute grinding involves removing a significant amount of material from the tool, which generates heat buildup, affecting tool life and performance.

Diamond mesh abrasives, a widely used material, play a significant role in enhancing the life of grinding wheel tools due to their exceptional hardness. However, it's crucial to use coated diamonds. Uncoated diamonds, despite their hardness, can wear down quickly when grinding WC due to the similar hardness of both materials. This can lead to heat transfer back to the grinding wheel bond, weakening it and causing premature dislodgement of the diamond particles. These heat-related issues and faster diamond wear can significantly reduce the lifespan of the grinding wheel. 

To determine the best-coated diamonds for WC flute grinding, Hyperion Materials & Technologies developed several simulation tests to identify which diamond coatings can best help prolong grinding wheel life. Tests were developed between copper, silver, and nickel coatings for the RVG diamond, which measured radial wheel wear, thermal conductivity, friction coefficient, and endmill performance. 

Hyperion's research has revealed the significant benefits of copper and silver-coated diamonds in boosting flute grinding wheel life. Download the tech note to understand how these coatings can be an excellent option for prolonging wheel life and increasing the number of parts per shift/day. Evaluate the tests and discover how these diamond coatings can help toolmakers grind parts faster and generate higher throughput.