Test Data on Fluting with BCA Bond & Derivatives

Tests were run on Walter & ANCA CNC Grinders.

Test Wheel: 1A1: 6x1/2 x 1-1/4; ND180-R100-BCA 1/4

3/4" Diameter - 4 Flute End Mill - 1-1/2" Flute Length
.200" Flute Depth
Cycle Time: 6:56 Minutes - Competition: 8 Minutes

Results: Held corner well, Good Finish

1" 4 Flute End Mill 1-1/2" Flute Length
.200 Flute Depth - 30° Helix
4700 SFPM; 85% Load
Cycle Time: 17 Minutes

Results: Comparable to competition with much better edge retention.

1" - 2 Flute End Mill
1- 1/2" Flute Length - .300" Depth
4700 SFPM
Cycle Time - 15 Minutes

Results: Comparable to competition with much better edge retention.

1A1; 5x1/2 x 1- 1-1/4; ND180-R100-BCA 1/4
1" - 2 Flute End Mills
1-1/2" Flute Length
3 Passes to Complete Grind
.075" / Pass
Time to Complete - 30 Minutes

1V1; 6x1/2 x 1-1/4; V=20 DE; ND180-T100-BCP1 1/4
3/4" 4 Flute End Mills
1-5/8" Flute Length
ANCA TGX 5 AXIS Grinder
Wheel Ran @ 2800 RPM or 4300 SFPM
Feed Rate of 5" Per Minute
50% on Load Meter
5 Minute Cycle Time

Results: No Dressing Needed After 80 Tools. Competetive Wheel Required 2 Dressings

1V1; 4x3/16 x 1-1/4; V=45°; ND220-T100-BCA 1/4
12 Flute Radius Cutters O.D. & Fluting
.800" Diameter
Walter Power Grinder 12 H.P.
Wheel Ran at 4500 RPM at Feed Rate of 11" Per Minute
Width of Cut - .200: Depth of Cut - .068" Feed Length of 1"

Results: 100 Tools per Dress Compared to 80 Tools with Competitors Wheel. Operator Comments: Very predictable wheel, very good wear & edge retention.

1V1; 4x1/8 x 1-1/4; V=20°; ND280-R100-BCA 1/4
Used on Unison 2600 Against a Polyimide Spec.
Grinding 1/4" Ball Burs with 10 Flutes
Water Soluble Coolant

Results: Performance comparable to Polyimide Wheel using same cycle times and feed rates. Wheel deemed acceptable.

1V1; 5x1/4 x 1-1/4; V=35°; ND220-R100-BCA 1/4
Wheel used on Walter 35 Oil Based Coolant
Fluting of solid acrbide slitter saws ganged on an arbor.
Stack is 3/8" to 1/2" thick.
Wheel ran at same speeds & feeds as current wheel.

Results: Customer able to grind twice as many parts per dress than current wheel.

1B1; 5x3/32 x 1-1/4; V=45°; ND400-R100-BCA 1/4
Wheel used on hydraulic feed fluting grinder (homemade).
Water soluble coolant.
Grinding fine pitch slitter saws with .060" pitch stacked on an arbor.
This wheel ran against one of older specs.

Results: Productivity increased two fold.

1A1; 6x1/2 x 1-1/4; BN180-T-BG 1/4
Wheel used on Walter grinder
Stainless steel surgical tools are ground.
On 455 stainless performance comparable to competition with feed rates, etc.

Results: On 17-4 stainless much better feed rates were obtained.

1A1; 5x1/2 x 1-1/4; BN150-T-BG 1/4
Used on Walter HMC500-25 H.P.
4700 RPM @ 3" per minute
Feed length of 2-1/2"
Fluting & cylindrical grinding of high speed tools.
Free cutting while maintaining excellent grinding characteristics.
Excellent edge retention on cylindrical spinning.

Results: Productivity with this bond increased by 50% over competition.