Performance Case Study of Vacuum Brazed Diamond Grinding Wheels in Cast Steel Surface Treatment

Case Study: How Vacuum Brazed Diamond Grinding Discs Transform Surface Finishing in Cast Steel Processing

For decades, the casting industry has relied on resin-bonded grinding tools for deburring and surface smoothing—yet these tools often wear out quickly, generate excessive dust, and fail to meet modern productivity demands. At Henan Yode Superhard Tools Co., Ltd., we’ve engineered a breakthrough solution: vacuum brazed diamond grinding discs that deliver superior performance, longer life, and safer operations.

Technical Edge: Why Vacuum Brazing Outperforms Traditional Bonding

The key lies in the manufacturing process. Unlike conventional resin-bonded wheels—which typically last 3–5 hours under heavy-duty use—our vacuum brazed diamond segments are fused directly onto steel cores using high-temperature brazing (up to 850°C). This creates an atomic-level bond that resists thermal shock, mechanical stress, and abrasive wear.

In field tests conducted across three foundries in China’s Henan province, our discs achieved an average lifespan of 24–30 hours per unit when used for cast steel deburring at 3,000 RPM. That’s 4–6x longer than standard resin tools—and with consistent cutting force throughout their life cycle. One customer reported reducing tool change frequency from every 2.5 hours to once every 7 hours, saving over 12 labor hours per shift.

Real-World Results: From Rough Castings to Smooth Surfaces

A leading automotive casting manufacturer in Zhengzhou adopted our 125mm x 10mm disc for post-molding edge finishing on gray iron and ductile iron parts. Before switching, they experienced inconsistent surface roughness (Ra values between 8–15 μm), requiring secondary polishing. After implementation:

• Surface finish improved to Ra ≤ 4 μm consistently
• Production speed increased by 22% due to reduced rework
• Dust emissions dropped by 60%, aligning with ISO 14001 environmental standards

Safety First: Dust-Free Operation & Operator Wellbeing

One major pain point in traditional grinding is airborne particulate matter—especially dangerous with cast steel residues. Our vacuum brazed design minimizes fragmentation during operation, producing up to 70% less fine dust compared to resin-based alternatives. Combined with optional integrated extraction hoods, this ensures compliance with OSHA and EU PPE regulations while improving workplace air quality.

“We no longer see respiratory complaints from operators,” said Zhang Wei, Maintenance Manager at a large foundry in Shandong. “The new system feels like a step toward Industry 4.0.”

Customization for Diverse Casting Needs

We offer multiple configurations tailored to different materials and processes:

Why Choose Yode? Innovation You Can Trust

At Yode, we don’t just sell tools—we build long-term partnerships. Every disc undergoes rigorous QC checks, including diamond concentration mapping, bond strength testing, and real-world trial validation. Our technical team provides on-site support, training, and lifetime access to application guides in English, Chinese, and Arabic.