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diamond limits is useful in certain conditions Diamond is made of carbon, and at high enough temperatures will burn, or will react with carbide-forming metals If either event occurs to any significant extent, the diamond structure is lost The service conditions that are required to avoid such losses are low temperatures and avoidance of carbide-forming metals except when close to the room temperature such as in lapping and polishing operations The high thermal conductivity of diamond helps to relieve the problem by conducting the heat away [15] Diamonds are excellent for machining non-ferrous metal (such as copper, zinc, aluminium and their alloys), plastics, ceramics, glass, fibreglass bodies, graphite and other highly abrasive materials Although diamonds are very hard, they get worn out when machining steel, titanium alloys and stainless steel because they consist of pure carbon The carbon in diamond dissolves in -Fe at a high rate at a temperature greater than 900 C [16] Diamonds are also not particularly effective for machining superalloys that contain cobalt or nickel probably because of the same reason as stated earlier [16] A recent study on grinding wear mechanisms has shown that the CBN wheel is superior to Al2O3 and SiC wheels due to the greater chemical stability of CBN at higher temperatures when grinding titanium alloy (Ti6Al4V) and nickel-based alloy (K417) [12] The use of tungsten carbide (WC) has been explained in the section on mounted wheels

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The size of an abrasive grain is identified by a number, which is normally a function of the mesh width of the sieve size either in microns or mesh openings per inch Figure 42 shows the equivalent

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grain size used by the FEPA (microns), ASTME 11 (inches), ISO and DIN (microns) standards for both diamond and CBN wheels In the metric system (microgrit size), the smaller the number, the smaller is the grit size However, the coding is reversed in the imperial system wherein a smaller number represents a coarser grit size

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The grade of a grinding wheel refers to its strength in holding the abrasive grains in the wheel This is largely dependent on the amount of bonding material used As the amount of bonding material is increased, the linking structure between the grains becomes larger which makes the wheel act harder A hard wheel has a stronger bond than does a soft wheel The type and the amount of bonding material in the wheel also influence the overall strength In standard marking systems, the grade of the grinding wheel is labelled as A Z (soft to hard)

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The structure of a grinding wheel represents the grain spacing and is a measure of the porosity of a bonded abrasive wheel Figure 42 illustrates the structure of a grinding wheel showing bigger pore areas (voids) in the open structure than in the medium and dense structure Porosity allows clearance space for the grinding chips to be removed for a proper cutting action during grinding operation If this clearance space is too small, the chip will remain in the wheel, causing what is known as wheel loading A loading cutting wheel heats up and is not efficient in the cutting action When this happens, a frequent dressing is needed to remove loaded workpiece particles on the wheel On the other hand, it is inefficient to have too large a space, as there will be too few cutting edges A dense structure has a strong grit holding power than does an open structure Some porosity is essential in bonded wheels to provide not only a clearance for the minute chips being produced but also to provide a cooling effect; otherwise, they could interfere with the grinding process In standard marking systems, the structure of the wheel is labelled by numbers Smaller numbers denote an open structure, whereas larger numbers represents denser structures Internationally, effort has been constantly made to minimize the variability of the grit spacing and the projection height of the grain in order to make the grinding process more predictable [19] [20] As illustrated in Figure 44, grain depths of cut and the space between grains are higher in (a) than in (b), and these are distinct advantages for effective grinding involving less loading and heat generation

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