1A1R Resin Bond Diamond Cutting Discs

1A1R Resin Bond Diamond Discs: Precision Deep Cutting & Grooving

Engineered specifically for demanding deep cutting and precision grooving applications, these 1A1R Resin Bond Diamond Cutting Discs (or Cut-Off Wheels) feature a unique composite structure. By combining a high-rigidity steel core with a specialized elastic resin bond diamond layer, they deliver exceptionally sharp, consistent performance and improved work quality when processing challenging materials like glass, ceramics, and hard metals.

Unique Construction: Rigid Steel Core with Elastic Resin Bond

This innovative composite design provides distinct operational advantages:

• High-Strength Steel Core: The robust steel core ensures exceptional rigidity and stability, even under the load of deep cuts or during high-speed rotation. This prevents disc deflection, maintaining cutting accuracy and straightness.
• Advanced Elastic Resin Bond: High-quality diamonds are embedded within a specially formulated elastic resin matrix. This advanced bond system contributes significantly to performance:
  • Self-Sharpening Action: The resin bond wears at a controlled rate during operation, continuously exposing new, sharp diamond cutting edges. This maintains consistent cutting efficiency and reduces the need for dressing.
  • Improved Work Quality: The inherent elasticity of the resin bond can dampen vibrations during cutting, leading to smoother cuts, finer surface finishes, and potentially reduced edge chipping, especially on brittle materials.

Optimized Profiles for Deep Cutting and Grooving

These discs are available in configurations specifically designed to excel in deeper machining operations:

• Two Work Layer Profile Options: Choose the geometry best suited for your task:
  • Equal Thickness Layer: The diamond resin layer has the same thickness as the steel core. This profile is ideal for achieving high precision in shallower grooves or performing precise cut-off operations where side clearance is less critical.
  • Thicker Work Layer (“Side-Relieved”): The diamond resin layer is intentionally made thicker than the supporting steel core. This creates crucial side clearance, significantly enhancing chip removal and coolant/lubricant delivery deep into the cut or groove. This design is essential for preventing binding and ensuring efficiency during deep cutting and substantial grooving operations.
• 1A1R Shape Advantage: The specified 1A1R shape, featuring a radius on the peripheral edge corners, can facilitate smoother entry and exit when plunge grooving, help generate specific profile shapes, or potentially reduce stress concentrations at the cut edge.

Material Suitability

These resin bond discs demonstrate excellent performance when cutting or grooving materials requiring a sharp cut and good finish, such as:

• Optical Glass, Technical Glass, and Quartz
• Advanced Ceramics (Alumina, Zirconia, etc.)
• Hard Metals, Cemented Carbides, and Tool Steels
• Certain Composite Materials requiring precise slotting.

Fully Customized Solutions

Due to the specialized nature of these applications, these discs are typically manufactured on a custom-order basis to ensure optimal results. To engineer the perfect cutting disc for your needs, we require detailed information regarding your specific application parameters:

• Workpiece Details: Material composition, hardness, dimensions.
• Operational Goals: Required cut depth, cut length, slotting vs. cut-off operation.
• Process Parameters: Single pass or multiple passes, machine type and model, available cutting speed (RPM or surface speed), feed rate, wet (coolant type) or dry cutting conditions.
• Desired Disc Specifications: Required Diameter (D – standard range 3″ to 14″), Thickness (T), Bore Hole size (H), Diamond Section Width (X), Diamond Section Depth/Height (E), Type (typically 1A1R, but 1A1 also possible), electrical conductivity requirements (if any), presence of slots or guide holes in the core, required cutting accuracy level, and tolerance for side damage/chipping.

Please provide as much known information as possible when inquiring.

Contact our application engineering team today to initiate the design process for your custom 1A1R resin bond diamond cutting solution.