Optical profile grinders (also known as PG grinders or optical curve grinders) are high-precision form-grinding machines that use optical projection magnification to machine complex curves, irregular contours, narrow slots, and internal/external radii to micron-level accuracy. They are widely used for precision molds (punches and dies), carbide tools, tungsten carbide components, connector terminals, LED/IC parts, and other high-precision workpieces. Correct grinding wheel selection directly determines machining accuracy, surface roughness, efficiency, and wheel life.
1. Core Principles for Optical Profile Grinding Wheel Selection
1.1 Abrasive Type
- Diamond (SD / SDC): Best for tungsten carbide, ceramics, cermets, and other hard brittle materials.
- CBN (Cubic Boron Nitride): Preferred for hardened steels, high-speed steels (SKH), tool steels (SKD, S136, DC53, etc.), and ferrous materials.
1.2 Bond Type
- Metal Bond: Excellent form retention and long life; the mainstream choice for high-precision profile grinding.
- Resin Bond: Better self-sharpening and superior surface finish; ideal for finishing and ultra-finishing operations.
1.3 Grit Size vs. Surface Roughness (Reference data from MORESUPERHARD)
| Grit Size |
Metal Bond Roughness (S) |
Resin Bond Roughness (S) |
Application Stage |
| 140–200 |
2.8–4.0 |
2.4–3.3 |
Rough grinding |
| 230–400 |
1.0–2.3 |
0.8–2.0 |
Semi-finishing |
| 600–1000 |
0.4–0.8 |
0.3–0.6 |
Finishing |
| 1500+ |
≤0.2 |
≤0.2 |
Ultra-finishing |
1.4 Nose Radius vs. Grit Size
| Grit Size |
Recommended Nose Width (mm) |
Nose Radius Range (mm) |
| 140–200 |
0.16–0.20 |
0.07–0.10 |
| 230–400 |
0.10–0.15 |
0.04–0.07 |
| 600–1000 |
0.06–0.08 |
0.02–0.03 |
| 1500 |
≈0.03 |
0.015–0.02 |
1.5 Other Key Parameters
- Concentration: Typically 100–150 (25–37.5% by volume).
- Peripheral speed: Recommended ≤ 50 m/s.
- Angle: Commonly 5°–20° (minimum 10° for smaller diameters; down to 5° for larger diameters).
- Run-out control: ≤ 0.005 mm.
2. MORESUPERHARD Optical Profile Grinding Wheel Recommendations
MORESUPERHARD specializes in diamond and CBN superabrasive wheels and offers both metal-bond and resin-bond optical profile grinding wheels compatible with WAIDA, Amada, Washino, Petewe, and other leading machines. Customization is fully supported.
Main Models and Specifications
| Model |
Outer Diameter D (mm) |
Width W/U (mm) |
Angle θ |
Nose Radius R (mm) |
Thickness T (mm) |
Bore H (mm) |
Grit Range |
Bond Type |
| 3A1 |
30–180 |
0.5–5 |
— |
— |
3–10 |
4.77 / 8 / 12 / 22.23 / 24 / 31.75 / 32 |
140–1000 |
Metal / Resin |
| 14K1 |
30–180 |
3–7 |
5°–20° |
0.03–0.2 |
3 |
Same as above |
140–1000 |
Metal / Resin |
| 1B9 |
30–180 |
3–10 |
5°–20° |
0.03–0.2 |
3 |
Same as above |
140–1000 |
Metal / Resin |
Typical Application Cases (MORESUPERHARD)
- Carbide molds: Metal-bond diamond wheel D180 × T8 × X1 × H31.75, 400#.
- Precision narrow slots (e.g., S136 tool steel): Metal-bond CBN 1000#, nose radius R0.02–0.03.
- Strong customization capability — angle, radius, bore, and grit can be tailored to drawings.
Key Advantages: Outstanding form retention, long service life, high precision, suitable for both dry and wet grinding. Widely used for precision mold and cutting-tool form grinding.
3. Matching Wheel Specifications for Leading Optical Profile Grinders
| Machine Brand & Model |
Recommended Outer Diameter (mm) |
Width (mm) |
Bore H (mm) |
Typical Angle / Radius |
Notes / Common Specs |
| WAIDA SPG-X / SPG-XV / PGX series |
100–160 (standard 120) |
3–10 |
22.23 / 24 / 31.75 |
5°–20° / R0.03–0.2 |
Compatible with MORESUPERHARD 1B9 / 14K1; mid-diameter wheels preferred for high-speed spindles |
| Amada GLS-80PL |
65–100 |
4–6 |
22.23 |
Single-V or Double-V 15° |
High-speed specification (TC-20 spindle, up to 20,000 rpm) |
| Amada GLS-150GL / GLS series |
120–180 |
3–10 |
31.75 |
V15° / R0.05 etc. |
Low-speed large-diameter specification (TS-6 spindle); Amada original TWD series or equivalent metal/resin wheels |
| Washino / Petewe / Doebeli |
75–150 |
5–10 |
22.23 / 31.75 |
10°–20° |
Similar to WAIDA; commonly uses 3A1 / 1B9 types |
Additional Notes
- Common bore sizes: 22.23 mm (high-speed mid-diameter) and 31.75 mm (standard large-diameter).
- Domestic examples (e.g., Dongju): 1B9 type 100D × 7W × 15° × R0.03 × T7 × 31.75H SDC1000 metal bond; 14E1 type 75D × 5T × 8H × 20V CBN1000.
- Always verify spindle speed range, flange compatibility, and cooling method (primarily dry grinding; some machines support wet grinding).
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- MORESUPERHARD can also provide vitrified bond PG wheels for efficient dressing of diamond rollers.
4. Practical Selection Tips and Precautions
- Match by Material: Tungsten carbide / hard brittle materials → Diamond metal bond; Tool steels / high-speed steels → CBN metal or resin bond.
- Match by Precision Stage: Roughing — coarser grit + higher concentration; Finishing — finer grit (800–1500#) + resin bond for better surface quality.
- Dressing and Operation: Metal-bond wheels retain form well but require regular dressing. Control depth of cut carefully to avoid nose chipping.
- Customization Preferred: For complex profiles or special radii, provide drawings to professional suppliers such as MORESUPERHARD for perfect machine matching.
- Safety and Life: Strictly observe peripheral speed limits; ensure proper wheel balancing and installation run-out control.
Selecting the appropriate grinding wheel and combining it with high-performance products from MORESUPERHARD, can significantly improving productivity. In practice, final selection should be validated through trial grinding based on specific workpiece drawings and machine parameters.
For detailed customized solutions for specific machines or workpieces, please consult professional grinding wheel suppliers.
