Superabrasive Grinding Wheels in Rotary Tool Manufacturing
Rotary Tools are cutting tools that rotate around their own axis during material processing.
This type of tool is widely used because it ensures high productivity and precision across various industrial processes and can be applied to almost all materials — metals, wood, plastics, composites, and more.
Rotary Tools are used for cutting, drilling, milling, threading, and other machining operations. The scale of their use continues to grow due to constant technological progress and improvements in tool performance.
Rotary Tools are manufactured from materials with high strength and wear resistance, such as:
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Tungsten carbide alloys (WC-Co)
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Titanium-based alloys (TiC, TiCN)
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Ceramics and cermets (metal–ceramic composites)
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High-speed steels (HSS)
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Zirconia ceramics, etc.
To improve reliability and durability, such tools are often coated with protective layers — e.g., titanium nitride (TiN) or diamond coatings.
In modern production, Rotary Tools are typically manufactured on high-precision CNC grinding machines, where the required geometry is formed.
These include machines by world-renowned brands such as Walter Helitronic Power, ANCA FX7 Linear, Rollomatic GrindSmart 630XW, Schütte 305 Linear, and others.
Superabrasives in Rotary Tool Production
The manufacturing process uses diamond and CBN (cubic boron nitride) grinding wheels, the two hardest materials known today — the two primary superabrasives.
At present, superabrasive wheels are produced on hybrid bonds, which combine the properties of metal and resin bonds.
Such bonds offer high durability (comparable to metal bonds) and excellent surface finish (comparable to resin bonds).
Rotary Tools come in many structural types, but the main grinding operations can be categorized as:
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Fluting (fluting, fluting grinding)
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Clearance grinding (relief or back angle grinding)
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Gashing
Fluting
Fluting is the main and most demanding operation in Rotary Tool production.
Since it involves heavy material removal, the process requires strong, straight wheel shapes such as 1A1 and 1V1.
The bond must have good edge retention while being capable of self-dressing during operation.
Clearance Grinding
This is a critical finishing stage of tool manufacturing that requires a high surface finish quality.
Typically performed using cup-shaped wheels — 11V9-70, 11V5-70, 12V5-45 — and, less frequently, straight-profile wheels.
The required bonds should ensure both edge stability and excellent surface finish.
Gashing
Gashing is a complex operation that requires a sharp wheel angle and high edge stability.
The classic choice for grinding the back angle on the tool end is a wheel with a 45° diamond layer angle — e.g., 12V9-45, 1V1.
This process is challenging because it involves a sharp 45° cutting geometry and significant material removal, demanding a high edge-retention bond.
PDTools Superabrasives Solutions (PrJSC “Poltava Diamond Tools”)
On the superabrasive tool market, PrJSC “Poltava Diamond Tools” has established a strong reputation.
We manufacture a full range of superabrasive wheels for various machining tasks on multiple bond systems.
For fluting operations:
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FPD01 – designed for machines with spindle power above 20 kW.
Ensures excellent profile stability at high cutting speeds.
Self-dressing is achieved at feed rates of 110 mm/min (for 100 mm wheels). -
RPD01 – a universal line for machines with spindle power from 7.5 to 20 kW.
Operates efficiently at medium speeds (100 mm/min for 10 kW and 150 mm/min for 20 kW). -
HPD01 – a multifunctional line suitable for 7.5–30 kW machines.
Designed for both fluting and free grinding operations.
For gashing and clearance grinding:
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VPD02 – intended for mass production, providing the best form retention.
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HPD03 – a universal bond for processing blanks of Ø6–22 mm.
Suitable for both serial and single-piece manufacturing of Rotary Tools.
Ensures superior surface finish and stable performance.