CUTTING OFF WHEELS

Cutting off wheels are usually manufactured in resinoid bond but Universal also supply a full range of
shellac and rubber bonded wheels for specific applications. Universal also produce a full range of rubber
bonded slitting wheels for cutting slots to tight tolerances.

Resinoid cutting off wheels are normally fabric reinforced. Unreinforced wheels can be used under the
following conditions, however:

 The machine must be fixed, not portable.

 The workpiece must be rigidly clamped.
 Wheel speed must not be greater than 80 m/s.
 Unreinforced wheels can be used for most toolroom applications but never on portable machines.

Bond Type

Resinoid Shellac Rubber

General purpose
Toolroom work
Metallurgical samples
High quality, burr free cut

Abrasive Type

Material Type
Cast General Non- Special High
Iron Steels Ferrous Steels Speed
Operation Steels
General
Purpose 13A 13A, 17A BC 13A, 17A 13A, 17A
Sample Cutting
Toolroom Work 12A 12A 12A 12A 12A
Rubber bonded
Wheels - 11A BC 11A 51A

Abrasive Size

Abrasive size selection is usually associated with bond type, since the factors that influence bond selection
also define the abrasive size range required. In general, the coarsest grit size possible should be used to give
maximum life, but finer grit sizes are necessary to reduce burrs. For thinner wheels, the maximum grit size
is governed by the wheel thickness and thin slitting wheels will have grit size in the range 180-500 grit.

Bond Grit Size

Type Application 24 30 36 46 60 80 10
0
Resinoid General Purpose
Toolroom Work
Shellac Toolroom Work
Rubber General Purpose
Tube Cutting
Grade

The application characteristics that influence the choice of bond type also determine grade selection which
is, therefore, associated with the bond type.

Wheel
Grade
U
T
S
R
Q
P
O
N
M
J
Material/ Cast H.S. Hard Tool Tool Sample General
Operation Iron Steel Steel room room cutting Tubes Purpose
work work
Material Type
Bond Type Resinoid Bond Shellac Bond Rubber Bond

Severity of Operation

Selection of both grade and grit size is effected by a change in the severity of the cutting operation.

Wheel Variation
Grade Grit Size
Large solid sections 1 grade softer No change
Large hollow sections 1 grade harder No change
Min. burr (resinoid wheels) No change 2 grit sizes finer
Low power machine 2 grades softer No change
Low speed machine 1 grade harder No change

General Recommendations

Application Specification
Portable Machines:
Steels A 30 SBF
Iron Castings A 30 SBF
Brass, soft bronze, aluminium C 24 SBF
Hard bronze A 30 SBF
Concrete, masonry C 24 SBF
Toolroom Work:
General purpose A 60 PB
High speed steel
- unhardened A 60 PB
- hardened A 60 NE
Lathe and planer tools A 60 NE
Twist drills A 60 NE
Metallurgical samples A 60 JE
Application Specification
Fixed Machines, Reinforced Wheels:
Concrete C 24 SBF
Clipper machines, masonry C 24 SBF
Non ferrous metals C 24 SBF
Steel forgings
- Small machines A 30 SBF
- Large machines A 248 TBFI
Iron castings A 30 SBF
Aluminium C 30 TBFE
Valve stems A 30 QBFE
Twist drill blanks A 30 QBFE
Fixed Machines, Unreinforced Wheels:
Investment castings slugs A 30 QB
General purpose A 30 TB
Metallurgical samples A 30 QB
Forging slugs A 36 TB
CYLINDRICAL GRINDING

External cylindrical grinding effectively results in line contact between wheel and work, giving minimum
grinding contact area. Increasing workpiece diameter relative to wheel diameter increases grinding contact
area, resulting in different wheel specifications being required.

Speeds and feeds will depend upon the power of the machine, workpiece material and finish required.

Abrasive Type

Severity of Operation
Material Medium/Heavy stock Light stock removal High production
Types removal fine tolerances rates
Soft Mild
Steels 48A, 11A 48A, 51A 48A, 11A
Medium Hard
Steels 48A, 51A 48A, 51A 48A
Hard
Steels WA WA WA
High Alloy
Steels 48A 48A 48A
Martensitic
Stainless Steel 48A, 51A 48A, 51A 48A, 51A
Tool Steels
Unhardened 48A WA 41A
Non-Ferrous Cast Iron,
Austenitic Stainless C C C

Abrasive Size

This table includes grit size selection for a required finish. The surface finish achieved is variable,
depending on dressing techniques, traverse speed, depth of cut, grade of wheel and type of material.

Surface Finish Grit Size

Ra µm CLA µin 36 46 60 80 120
1.6 63
1.4 55
1.1 42
0.8 32
0.7 26
0.5 21
0.4 16
0.35 14
0.25 11
0.20 8
0.17 7
0.14 6
Minimum Imp. 0.040 0.030 0.020 0.015 0.008
Workpiece Metric 1.00 0.75 0.50 0.40 0.20
Radius

The table above is for traverse grinding. For plunge grinding select one grit size finer to maintain surface
finish.
Grade

This table shows the normal grade selections for cylindrical grinding materials of different hardness. The
shaded area shows the preferred grade selection for the hardness ranges shown.

Wheel
Grade
N
M
L
K
J
I
H
G
Soft Medium Hard Pantograph
<50 Rc 50-57 Rc 58-63 Rc Attach-
Material Hardness ments

Severity of Operation

Wheel Variation
Grade Grit Size

Rough cast or forged condition 1 grade harder 1 size coarser

Interrupted cut, e.g. splines 2 grades harder 1 size finer

Large diameter workpiece 1 grade softer 1 size coarser

Small diameter workpiece 1 grade harder 1 size finer

Wide wheel, light pressure 1 grade softer No change

Narrow wheel, high pressure 1 grade harder No change

General Recommendations

General Steels

Material Hardness
Surface <50 Rc
Finish µin CLA >58 Rc 50-57 Rc Large Dia. Small Dia.

Commercial 32 48A 46 JV 48A 46 KV 48A 46 LV -

Good Commercial 20 48A 60 JV 48A 60 KV 48A 60 LV 48A 60 MV

Improved <20 - 48A 80 KV 48A 80 LV 48A 80 MV

Other Steels and Metallic Materials

Chrome Plating, Austenitic Stainless

High Speed Steel, Steel, Cast Iron, Sprayed
Surface Hardened Tool Steel Deposits, Non-ferrous Metals
Finish
µin CLA Large Dia. Small Dia. Large Dia. Small Dia.

Commercial 32 WA 46 JV WA 46 KV GC 46 JV GC 46 KV

Good Commercial 20 WA 60 JV WA 60 JV GC 60 JV GC 60 KV

Improved <20 WA 80 KV GC 80 JV

Application Specification
Aluminium shafts GC 60 JV
Camshaft journals – cast iron GC 60 KV
Crankshaft stub ends 48A 60 KV
Twist drill shanks 48A 60 KV
Gauges WA 60 JV
Lathe centres 48A 60 KV
Splined shafts
- hardened 48A 60 LV
Steel shafts
- unhardened 48A 46 LV
- hardened WA 60 JV
Stainless steel
- martensitic (magnetic) 48A 60 JV
Stellite – castings WA 60 JV
Valves 48A 60 MV
Tap shanks 48A 60 KV
Tungsten carbide
- milling cutters GC 80 JV
FETTLING

Fettling demands high stock removal rates combined with good durability to minimise abrasive costs.

Universal’s fettling wheels are specially formulated in the latest resinoid bonds to give free cutting
properties with maximum durability.

Abrasive Type

Zirconia mixtures are used for high production rates and maximum durability on heavy duty machines for
fettling iron and steel castings.

Regular aluminium oxide is used where better finishes are required and on portable machines. In general,
there is no benefit in using zirconia abrasives on wheels softer than ‘P’ grade. Silicon carbide is used on
non-ferrous metals and on portable machines.

Operation

Material Pedestal Swing Frame Portable

Types Machines Machines Machines

Grey Iron 63A 64A BC, AC

S.G. Iron 63A 63A 12A, AC
Malleable Iron 63A 63A 12A
Carbon Steel 63A 63A 12A
Stainless Steel 12A 12A 12A
Non-ferrous BC BC BC

Abrasive Size

Operational Variable Grit Size

12 14 16 20 24 30 36
Pedestal Machines:
Large castings
Medium castings
Small castings
Edge tools
Swing Frame Machines
Portable Machines:
Cup wheels
Wheels up to 63mm dia
Wheels over 63mm dia
Hardness testing
Grade

Because of the severe nature of the operations all fettling wheels are manufactured in hard grades. Different
materials require different grades, however, partly due to the hardness of the material and partly due to the
nature of casting flash, pads and risers that are associated with the different materials.

Wheel
Grade
S
R
Q
P
O
N
M
Grey Iron Malleable Non- Stainless
S.G. Iron Iron & Steel ferrous Steel
Material Type

The table shows the normal grade selections for fettling castings of different materials. The shaded area
shows the preferred grade selections for the hardness ranges shown.

Severity of Operation

Operational Variable Wheel Variation

Portable machines 2 grades softer
Medium size castings 1 grade softer
Small castings 2 grades softer

General Recommendations

Portable Machines – Plain Wheels

Wheel Diameter Hardness

100-150mm 63-100mm <63mm Testing
Fast cut A 16 QB A 20 QB A 24 QB -
Maximum life A 16 RB A 20 RB A 24 RB A 36 RB

Portable Machines – Depressed Centre Wheels

Application Specification
Steel, iron castings
- fast cut, low powered machines A 30 SBF Fascut
Hard bronze A 30 SBF Fascut
Brass, soft bronze C 24 SBF Fascut
Stone, concrete C 24 SBF Fascut
Steel castings
- sharp casting flash A 24 U6BFD Unilastic
Iron castings
- sharp casting flash C 24 U6BFD Unilastic
Fixed Machines

The following recommendations are for general purpose use. High volume foundry applications need
wheels specifically designed to suit customer requirements and we advise you to contact the Universal
Technical Advisory Service to discuss the most appropriate wheel for your application.

Application Specification
Steel billets, swingframe machine 63A 14 TB
Steel A 14 RB
Malleable iron A 14 QB
Grey iron C 16 QB
SURFACE GRINDING

Surface grinding demands cool, free cutting grinding wheels. The range of wheels offered by Universal for
surface grinding are specially formulated in open structure vitrified bonds to give optimum cool, fast cutting
properties allied to good form holding.

Severity of Operation
Light, medium or Light stock High
Material heavy stock Removal - fine production
Types removal tolerances rates
Soft Mild
Steels MA MA MA
Medium Hard
Steels MA MA MA
Hard
Steel WA WA WA
High Alloy
Steels MA WA 41A
High Speed
Steel, Ferritic Stainless MA WA 41A

Abrasive Type

Severity of Operation
Light, medium or Light stock High
Material heavy stock Removal - fine production
Types removal tolerances rates
Tool Steels
Unhardened MA WA 41A
Non-Ferrous Cast Iron,
Austenitic Stainless C C C

Abrasive Size

Surface Finish Grit Size

Ra CLA
µm µin 36 46 60 80 120
1.6 63
1.4 55
1.1 42
0.8 32
0.7 26
0.5 21
0.4 16
0.35 14
0.25 11
0.20 8
0.17 7
0.14 6
Minimum Imp. 0.040 0.030 0.020 0.015 0.008
Workpiece Metric 1.00 0.75 0.50 0.40 0.20
Radius
This table indicates grit size selection for a required finish. The surface finish achieved is variable,
depending on dressing techniques, traverse speed, depth of cut, grade of wheel and type of material.

Wheel
Grade
K
J
I
H
G
Material Soft Medium Hard Pantograph
Hardness <50 Rc 50-57 Rc 58-63 Rc Attachments

This table shows the normal grade selections for surface grinding materials of different hardness.

The shaded area shows the preferred grade selection for the hardness ranges shown.

Severity of Operation

This table shows recommended changes to both grade and grit sizes. In less severe conditions, modify only
the grade.

Wheel Variation
Grade Grit Size

Rough cast or forged condition 1 grade harder 1 size coarser

Small surface area or

light/broken table loading 1 grade harder 1 size finer

Medium surface area of

medium table loading No change No change

Large surface area of

high/heavy table loading 1 grade softer 1 size coarser

Wide wheel,
Light pressure 1 grade softer No change

Narrow wheel,
High pressure 1 grade harder No change
General Recommendations

Peripheral Grinding
General Steels
WA Abrasive

Material Hardness
Surface Finish <45 Rc 45-50 Rc 50-57 Rc 58-63 Rc
µin CLA Abrasive
MA WA

Commercial 32 MA 46 JV WA 46 KV WA 46 JV WA 46 IV WA 46 HV

Good Commercial 16 MA 60 JV WA 60 KV WA 60 JV WA 60 IV WA 60 HV

Improved 11 WA 80 KV WA 80 JV WA 80 IV

41A Abrasive

Material Hardness
Surface Finish <45 Rc 45-50 Rc 50-57 Rc 58-63 Rc
µin CLA

Commercial 32 41A 46 KV 41A 46 JV 41A 46 IV 41A 46 HV

Good Commercial 16 41A 60 KV 41A 60 JV 41A 60 IV

Application Specification
Aluminium GC 60 JVO
Cast Iron GC 46 JV
Chasers WA 46 IV
Diaform grinding
- 0.4mm form radius WA 100 GV
- 0.12mm form radius WA 120 GV
- 0.10mm form radius WA 150 GV
Dies WA 60 HV
Gears WA 46 IV
General purpose
- commercial finish MA 46 JV
- good commercial MA 60 JV
Nimonic WA 46 HV
Reamer blades WA 60 IV
Snap gauges WA 60 JV
Spline shafts WA 60 JV
Steels
- high speed 41A 46 JV
- stainless, ferritic MA 46 Jv
- stainless, austenitic GC 46 JV
Stellite WA 60 IV
Face Grinding with Cup and Ring Wheels

Application Specification
Cast Iron WA 30 IV
Metallurgical samples
- Abwood machine WA 24 HB
- cup wheels WA 36 IB
Slideway grinding WA 362 GV
Snow cup machines
- steel A 24 LV
- cast iron C 24 MV
Steels
- unhardened WA 30 JV
- hardened WA 36 HV
- stainless, ferritic WA 46 JV
- stainless, austenitic WA 36 IV
- high speed WA 30 HV
Stellite WA 36 JV
Wadkin machines
- general purpose WA 30 HB
- shear blades A 46 KB
TOOL AND CUTTER GRINDING

Sharpening cutting tools on mechanical tool grinders is virtually always performed with vitrified wheels.
The exception is cutting off lathe and planer tools, where shellac bonded cutting off wheels are used.
Coolant is not generally used since water may cause cracking due to excessive cooling rates at the cutter
edge.

Light cuts (0.05mm-0.08mm roughing and 0.01mm finishing) with fast traverse rates result in less heat
generation in the cutter edge than heavy cuts with slow traverse rates.

To ensure maximum rigidity and accuracy, there should be less than 1mm clearance between the grinding
wheel and the tooth rest. Contact between tooth and rest should be directly opposite the point of grinding
contact.

Bond Type
Bond Type
Vitrified Shellac
General
Cutting off

Abrasive Type
Operation
Material Types Offhand tool Sharpening Cutting Off Precision Grinding
High Speed Steels,
M Series tool steels A A WA
D and T series Tool
Steels A A 41A
Tungsten Carbide
GC - GC

Abrasive Size
This table indicates grit size selection for a required finish. The surface finish achieved its variable,
depending on dressing techniques, traverse speed, depth of cut, grade of wheel and type of material.
Material
Material

Operation Grit Size

36 46 60 80 100 120 220

Offhand grinding
- coarse
- medium
- fine
Steels

Drill sharpening
- drills >5mm dia
- drills <5mm dia
Saw sharpening
- coarse teeth
- fine teeth
Cutters, Reamers and
Broaches
Tungsten
Carbide

Roughing
Finishing
Lapping
Grade

These tables show the normal grade selections. The shaded area shows the preferred grade selection.

(i) Offhand Grinding

Wheel
Grade
P
O
N
M
L
K
J
I
Roughing Finish Rough Finish
Material/ Twist
Component Steel Tools Drills Carbide Tools

(ii) Mechanical Tool Grinding

Wheel
Grade
N
M
L
K
J
I
HSS & M D&T Rough Finish
Cutting Drills & Series Series
Operation Off Saws Cutters Carbide

Severity of Operation

This table shows recommended changes to both grade and grit sizes. In less severe conditions, modify only
the grade.

Wheel Variation
Grade Grit Size

Drill sharpening with disc wheels 1 grade softer No change

Mechanical tool grinding 1 grade softer 1 size coarser

chipped tools

Large contact areas 1 grade softer No change

Fine finishing 1 grade softer 1 size finer

General Recommendations

Mechanical Tool Grinding

High Speed Steels

Contact Area Carbon Steels 56-60 Rc >60 Rc Tungsten Carbide
Large WA 46 KV WA 46 JV WA 46 IV GC 60 JV
Medium WA 60 KV WA 60 JV WA 60 IV GC 100 JV
Small WA 80 KV WA 80 JV GC 120 JV

Pink Abrasive

High Speed Steels

Contact Area Carbon Steels 56-60 Rc >60 Rc
Large 41A 46 KV 41A 46 JV 41A 46 IV
Medium 41A 60 KV 41A 60 JV 41A 60 IV

Offhand Tool Grinding

Tungsten Carbide
Application Carbon Steels High Speed Steel Large Tools Small Tools
Roughing A 36 Hard V A 36 Hard V GC 46 JV GC 60 JV
Semi-finish A 46 Hard V A 46 Medium V GC 60 JV GC 80 JV
Finish A 60 Hard V A 60 Medium V GC 100 IV GC 120 JVO

Lumsden Machine, Tungsten Carbide Tools

Application Specification
Shanks A 36 Medium V
Roughing GC 46 LVO
Semi-finish GC 100 JV
Finishing GC 220 JV

Optical Profile Grinding

Form Radius Tools and High Tungsten Carbide

(mm) Speed Steel And Die Steels
>0.40 WA 100 KV GC 100 KV
0.20-0.40 WA 120 KV GC 150 KV
015-0.20 WA 150 KV GC 150 KV
0.10-0.15 WA 220 KV GC 220 KV
Drill Sharpening

Application Specification
General purpose A 60 Medium V
Z. Brierley machines
- 180 x 25 x 25.40, 1 recess MA 46 KV/
MA 100 LV
- 200 x 42 x 31.75, 1 recess 41A 46 IV
- 235 x 100 x 127mm
Straight cup 41A 46 KV
Dormer Machine
- 200 x 6 x 31.75mm Point
Splitting WA 100 LV
- 200 x 25 x 101.6mm Grinding WA 46 LV
- Grinding & Splitting WA 46 LV/
WA 100 MV
- 203 X 50 X 114.3mm I.N. Disc WA 46 KV

Saw Sharpening

Steel Type Coarse Teeth Fine Teeth

High speed steel WA 46 LV A 60 MV
Carbon steel A 54 MV A 60 MV

Tool and Cutter Grinding

Application Specification
Broaches, high speed steel 41A 60 JV
Chasers, high speed steel WA 120 JV
Dies, high chrome steel WA 46 HV
Drills, high chrome steel WA 46 KV
Gauges, tool steel WA 80 JV
Gear cutters
- Gleason machine MA 180 JV
- Hurth machine MA 120 JVO
- Klingelnberg machine WA 60 HVO
Lathe and planer tools WA 60 KV
Reamers WA 60 JV

Minimum Spindle Diameters for Bench Grinders and Pedestal Machines

The following table shows the minimum metric diameters of machine spindles for various diameters and
thicknesses of grinding wheels operating at speeds up to 35 m/s.

Wheel Wheel Thickness (mm/in)

Diameter 13 20 25 32 40 50 63 80
mm in ½ ¾ 1 1¼ 1½ 2 2½ 3
150 6 12.70 12.70 12.70 15.88 15.88
180 7 12.70 15.88 15.88 15.88 19.05 19.05 19.05
200 8 15.88 15.88 15.88 19.05 19.05 25.00 25.00
230 9 15.88 19.05 19.05 19.05 19.05 25.00 25.00
250 10 19.05 19.05 19.05 19.05 19.05 25.00 31.75
300 12 19.05 25.00 25.00 25.00 25.00 31.75
356 14 25.00 25.00 31.75 31.75 31.75 31.75 38.10
406 16 31.75 31.75 31.75 31.75 31.75 38.10 38.10
457 18 31.75 31.75 31.75 38.10 38.10 38.10 38.10
508 20 38.10 38.10 38.10 38.10 38.10 44.45