Abrasive grains are available in a wide range of grit sizes and bonding agents. Determining which wheel is right for the job requires considering seven key factors:
For more information, please visit Leading Diamond Tools.
The first thing to consider when selecting a grinding wheel specification is the workpiece material type and hardness. Is the material easy or difficult to grind? The relative ease of grinding is a major predictor of the appropriate abrasive type, grain attribute, grit size and bond type for the application.
By convention, aluminum oxide grains are used for grinding ferrous metals, and silicon carbide grains for non-metals and non-ferrous metals. Ceramic and superabrasive grains are compatible with all three types of materials, but are typically meant for specific circumstances where aluminum oxide and silicon carbide perform poorly.
With the grain type is established, material grindability determines many of the other necessary attributes for the grinding wheel. If the material is easy to grind, use a tough, durable grain. Since the material is easy to grind, grains shouldn’t break down too soon or too easily, so the whole grain can be used to maximize wheel life. A coarser grit is best for these materials, as the grains can easily penetrate the material and maximize stock removal. A harder grade (that is, a harder bond between the grains and the wheel) also corresponds to easier grinding, as the bond will prevent the wheel from releasing the grains before they are consumed.
For hard-to-grind materials, reverse these recommendations. Mild, friable grades perform better on these materials, as they fracture more easily and stay sharper. Finer grit sizes improve the ability of the particles to penetrate hard materials and form chips. Because the grits will dull and cause metallurgical damage such as burning if held for too long, soft grades are necessary to release dulled grains and expose the material to sharper ones.
Users should also consider the grinding pressure, or force per grain. The higher the pressure, the more severe the operation, and the better ceramic and superabrasive grains are likely to perform. The severity of the operation also helps determine the attributes of the abrasive grain.
Tough, durable grains are able to tolerate higher levels of pressure and not break down prematurely. Coarser grits also assist the grains in holding up to grinding pressure. There may be times where distributing the pressure over more cutting points is best, but even that situation requires balance to prevent the pressure from turning the finer grains into dust. Heavy pressure also requires harder grades so grains can stay on the wheel long enough to perform the required grinding work.
In contrast, mild, friable grains perform better in light-pressure operations, since durable grains will only rub and dull. Finer grit sizes ensure that the grains can still fracture properly and self-sharpen, and softer grades release dulling grains before they begin to rub and burn the material undergoing grinding.
Grinding wheels achieved their ubiquity due to their speed, form repeatability and ability to achieve desired finishes. When selecting a wheel, it is important to determine whether the application requires rapid stock removal or a fine finish. Equally important is whether the part will be simple and flat, or if there is a form to hold.
The required surface finish, dimensional tolerances, form holding requirements and stock removal rates factor into the appropriate grit size, grade and bond type.
For low-Ra finishes or close geometric tolerances, finer grits are helpful because they provide more points of contact between the work and wheel. This helps with precision finishes, which have a shallower scratch pattern and a lower micro-inch finish. Finer grains also aid in achieving and holding small-radius and complex forms. Coarser grits, by contrast, improve stock removal rates. Finding the optimal balance in grit size will decrease cutting cycle times.
Close geometric accuracy and form holding requires a harder grade. Harder grades enable the wheel to hold its profile longer and ensure the grains are held long enough to achieve the desired results.
This next recommendation may seem contradictory, but softer bonds are optimal for both finer finishes and higher stock removal. A wheel with a softer bond will easily release dull grains and keep newer, sharper grains in contact with the material. Sharper grains increase stock removal and improve finish by preventing dull abrasives from rubbing and burning the part during stock removal operations. Although the actual finish and stock removal rates from this operation are primarily dependent on grit size, keeping sharp grains in the grind zone benefits both.
Part requirements also determine the bond type. Vitrified wheels perform best for close tolerances and form holding, while organic and resin bonds are best for reflective and other fine finishes. Organic bonds, unlike vitrified bonds, have a little give to them. Some of the grinding forces go into the bond, reducing the chip size. Another benefit for fine finish grinding is the way organic bonds break down from the heat of the grind. They tend to hold grains a little longer, allowing them to run and dull. Planned plowing and sliding interactions that take place under these circumstances improve upon the initial scratch pattern formed during stock removal to generate a finer finish.
Area of contact is partly related to severity of operation in that it considers the area of contact between the work and the wheel. When a wheel is applied to the work, the force applied is distributed over all the cutting points in the grind zone. The larger the area of contact, the lower the force per grain. Conversely, the smaller the area, the higher the force per grain.
Operations with a small area of contact should use tough, durable grains that will not fracture too early or suffer premature wear under higher force per grain. Ceramic or superabrasive grains may even be necessary in these operations. Finer grit sizes are optimal for small areas of contact, because in addition to providing more abrasive points at the area of contact, the relative pressure or grinding forces will be split among many grains. The high forces of operations with smaller areas of contact also call for harder-grade wheels, as these will hold their shape against premature wheel wear.
When the area of contact increases and becomes larger, such for a Blanchard segment, milder grains are more appropriate. Due to the increased number of grains in contact with the work in the grind zone, the force per grain is lower and the grains will fracture and self-sharpen more easily. Coarse grits spread the pressure into fewer grains to ensure they will continue to penetrate the work. As the risk of burning from dulled grains is higher in these operations, softer wheels grades should be used so grains release before doing damage to the part.
Operations’ wheel surface speeds can narrow down the bond type and wheel grade necessary to complete them. To calculate surface speed, use these equations:
Surface Speed (SFPM) = (π × Diameter (inch) × RPM) / 12
Surface Speed (m/s) = (π × Diameter (mm) × RPM) /
Wheel speed determines what bond type is best for the required speed, or if a special high-speed bond might be required.
As a general rule:
Wheels will also act differently based on their speed. For every 1,000 SFPM (5.08 m/s) the surface speed changes, the wheel will act one grade harder or softer. Slower wheel speeds equal softer performance, as the higher force per abrasive particle causes the grains and bond to break down quicker. Faster wheel speeds lead to harder performance, with the lower force per abrasive particle making the grains and bond act more durable.
Coolant in a grinding system affects vitrified and organic (resin) bonded wheels differently, and plans for its use must be considered when determining the wheel's grade or hardness.
If you are looking for more details, kindly visit Hand Held Profile Wheels.
If coolant is used:
If no coolant is used:
The horsepower of the grinding machine can play a role in determining the grade of the bond or the hardness of the wheel.
Due to how many factors are involved in determining the starting specification for a grinding wheel, there will be situations when factors point in opposite directions. In such cases, look at where the majority of the factors are pointing, or place precedence on the most important factors for the application. For simple comparison, review the chart below:
Plate casters are one of the most reliable and versatile caster types used in industrial, commercial, and institutional settings. At CasterCity.com, our plate casters feature a flat metal mounting plate with pre-drilled holes that allow for secure attachment to a wide range of equipment and furniture. Our extensive selection of plate casters includes a variety of wheel materials, load capacities, and sizes to meet your exact requirements. From light-duty plate casters for office furniture to heavy duty industrial plate casters built for demanding environments, our casters are designed to deliver quality and performance. Whether you’re outfitting carts, machinery, or mobile workstations, our plate casters provide the exact support and smooth mobility your operation needs. We try and give you all the information you need but if you cannot find something that will work, call us at 800-501- and our expert staff will help you with your caster purchase.
Stem Casters are a type of caster wheel that mounts to equipment using a stem rather than a mounting plate and makes them ideal for applications with limited mounting space available. They come in various stem types including threaded, grip ring, expanding rubber, and metal (square/round). Each stem module type is designed to fit different tubing or frame structures and allow for smooth mobility. Stem Casters are most commonly used on carts, furniture, and medical equipment. We offer stem casters with load capacities as small as 250 lbs and as strong as 1,500 lbs, with many pedal and foot brake options available.
We have a stem caster for any need and if you cannot find the right caster, please contact us directly (Call: 800-501- / : ) and we can help you find the perfect stem and caster for your application.
Total locking brakes are a popular choice when safety and stability. We offer brakes on both stem and plate casters. These brakes are designed to lock both the wheel and the swivel at the same time, so once they’re engaged, the caster won’t roll, pivot, or move.
Total locks are widely used in a variety of settings such as warehouses, medical facilities, food service environments, and even heavy duty industrial settings. They’re the perfect caster for mobile equipment that needs to be rolled into place and then stay firmly in position carts, racks, prep tables, or mobile workstations.
If you’re not sure what kind of brake or caster setup works best for your home or business needs, our Caster City sales team is here to help. With decades of experience, we’ll guide you to the right solution for your application and make sure you get exactly what you need for the job.
Stainless steel casters, offered in both plate and stem mounting styles, are built for use in wet, corrosive, or high-temperature environments where durability and cleanliness are critical. These casters are available in both 304 and 316 stainless steel—the former offering strong corrosion resistance for general industrial and food service use, and the latter providing superior protection against harsh chemicals and saltwater, making it ideal for marine and pharmaceutical applications. Designed to handle temperatures up to 450°F when paired with high-temp wheels and raceway seals, these casters perform reliably in extreme heat such as in autoclaves or commercial ovens.
Caster City’s stainless steel casters are built with longevity and performance in mind. Each unit includes a grease fitting in the swivel bearing for easy maintenance, protective seals, and a dust cover to guard internal components from contaminants. Whether you choose 304 for its broad utility or 316 for its maximum corrosion resistance, these casters ensure smooth, low-maintenance mobility in the most demanding conditions.
These industrial pneumatic casters feature air filled pneumatic wheels. These industrial casters are designed for low speed manually moved applications only. Air filled pneumatic wheels provide a cushioned ride, shock absorption and quiet operation. Pneumatic casters are ideally suited for moving fragile or delicate cargo where caster overall height is not critical. Casters with pneumatic wheels are usually the best choice for use outdoors over rough surfaces ( i.e. gravel ) or on grass. The wide footprint on 8″ or larger pneumatic wheels provides stability on gravel and does not sink into lawns.
Pneumatic casters and pneumatic wheels are also popular for indoor use in places such as hospitals, scientific and electronic laboratories, hotels, department stores and TV or movie studios.
Pneumatic wheels with black tires do not mark the floor as long as the wheel is allowed to roll. Changing directions without allowing a swivel caster to turn gradually around, or dragging a black rubber wheel sideways, can mark some floors.
To assist you, our customers in locating the ideal caster (stem or plate) for your particular business need, our comprehensive catalog has been carefully arranged. We provide a broad range of solutions to satisfy the needs of the manufacturing, healthcare, retail, and service sectors.
We offer a wide range of products for the industrial sector, including light-duty and low-profile plate casters for machinery and equipment. Our casters are designed to withstand severe weights and precise movement, making them perfect for jacks, service equipment, and shop floors in the automotive and aerospace industries.
While our medical and laboratory casters satisfy the hygienic and silent-rolling requirements needed for hospitals, labs, and pharmaceutical facilities, those in the food and beverage industries will find alternatives designed for production lines, meat processing, and shopping carts.
Additionally, we have casters for retail and hospitality applications, including luggage carts, vending machines, and bakery racks. Durable variants designed to withstand big loads and tough terrain are supported for outdoor and agricultural applications.
Our specialty casters include dual-wheel models for enhanced stability, ergonomic solutions, vintage designs, and black e-coat finishes for more specific applications. We also provide casters for toolboxes, utility carts, hand trucks, and other material handling and storage applications.
We provide dependable mobility solutions for a variety of industries, ranging from stage and theatrical equipment to maintenance tools like mop buckets and camper supports. With targeted caster options, even specialized applications like road cases, ladders, and textile machinery are taken into consideration.
Regardless of your application, our expert sales staff, with a collective experience of over 100 years are available to assist you in locating the best caster to complete the task quickly and effectively.
Looking for expert advice on choosing the right casters, installing your casters, or maintaining your equipment? Our blog at Caster City features helpful how-to articles that break down everything from selecting the best caster for your needs to understanding brake types, weight capacities, wheel materials, and industry use. We also include news from time to time on the latest innovations that are impacting many of our customers. Read on by clicking on the Left Side tabs to and let us know if you need help with anything. We are here to help.
Contact us to discuss your requirements of CNC Profile Wheels. Our experienced sales team can help you identify the options that best suit your needs.