Client Overview
An established Israeli mining equipment manufacturer (Urdan) specializes in heavy‑duty mining machinery components. The client processes large 3×3 meter low‑alloy steel (Cr‑Ni‑Mo) parts (quenched & tempered) on VULKAN grinding stations, seeking a high‑performance upgrade from conventional abrasive wheels.
Challenge
- Workpiece: Large 3×3m low‑alloy Cr‑Ni‑Mo steel (quenched/tempered)
- Original tool: Standard abrasive grinding wheels (Norton)
- Main issues: Low removal rate, frequent wheel replacement, high downtime
- Requirement: Larger diamond grit for faster stock removal and longer service life
Our Custom Brazed Diamond Solution
Based on the client's wheel dimensions and grinding process video, we engineered a custom brazed diamond grinding wheel with:
- Grit size: 25/30 (coarse, for aggressive material removal)
- Brazed diamond technology: Strong grain retention, high exposure, free cutting
- Custom design: Matched to VULKAN station, 12 segmented layout, precise dimensional tolerance
Key Advantages Over Conventional Wheels
✅ 2–5× longer service life
✅ 30–50% higher material removal rate
✅ Less downtime, fewer wheel changes
✅ Stable cutting for large heavy steel parts
✅ Reduced overall grinding cost
Technical Specifications
- Outer diameter: 590 mm
- Inner diameter: 477 mm
- Thickness: 50 mm
- Segment count: 12
- Grit: 25/30 (coarse)
- Bond: Brazed (high strength, high exposure)
Result
The custom brazed diamond wheel perfectly matches the client's heavy‑grinding requirements. It delivers aggressive cutting, stable performance, and significant cost savings for large low‑alloy steel mining components.
