Cutting grains used in bonded abrasive gear grinding wheels include aluminum oxide, silicon carbide, zirconia alumina and ceramic alumina. Typically, grains are based on the materials being cut, the buildup of heat and the costs. Some grains are much more aggressive and provide faster cutting combined with just the right bonding technology. “The reason our technology works so effectively is because we were able to have as little bond on the wheels as possible and the most grain to cut and remove material,” Brown added. “If you have the right bond system, you’ll have a positive impact on the wheel’s lifespan as well as its cutting rate.”

Harder bonds typically have a longer lifespan and are better for softer materials, while softer bonds have a shorter lifespan but shed grains more quickly, providing a faster cut. Weiler Abrasives’ V59 bond technology, for example, ensures exceptional results and addresses customers’ unique needs with flexibility and precision. The advanced formulation of V59 bond technology provides superior grain retention, improving wheel life and grinding efficiency. Dynamic porosity lowers grinding temperatures through increased coolant efficiency and greatly reduces part surface damage from heat distortion while aiding in material removal rates — allowing for a reduction in grinding cycle times. The extended wheel life delivered with V59 bond technology also improves profile retention and reduces dressing frequency.

The right grain combination generally results in a better surface finish.

Shortening Lead Times and Optimizing Performance 

In 2024, Weiler Abrasives launched an express program cutting lead times for gear grinding wheels from months down to days. The program was designed to help gear manufacturers in industries such as automotive, energy and aerospace improve quality, increase consistency and deliver on time to their customers. The priority was on-time delivery, an area where many vendors have struggled to keep up with demand. With a sizable stock inventory of over 120-wheel blank sizes and specifications at Weiler Abrasives’ North American headquarters in Pennsylvania, custom wheels can be produced within weeks. Available sizes range from as small as 6 inches up to 24 inches in diameter and from 1/2 inch to 9 and 1/2 inches thick. The state-of-the-art wheel profiling cell allows for wheel speed testing to ANSI B7.1 safety standards, which is 1.5 times the maximum operating speed labeled on the wheels, ensuring the ultimate safety of the product for the consumer. Elevating industry standards, Weiler’s premium manufacturing quality of precision grinding wheels feature tighter dimensional and imbalance tolerances, resulting in less vibration and very little dressing required when they are mounted on a customer’s machine. “The flexibility of our wheels is perfect for a customer like AGW where they may work on a damaged gearbox, a complete rebuild and a regrind all in the same week. High-demand situations in paper mills require custom designs and we were able to provide a much more consistent delivery schedule.” Brown believes the collaboration between both companies will grow in the coming years. “Performance was a huge factor in this partnership,” Brown said. “The goal was to reduce cycle times and lower the onsite tooling inventory to free up valuable space. Cycle time went from 24 hours to 18 and we increased grinding wheel life in the process. This was a win-win for both organizations. We met the needs of our valued partner and learned some unique benefits of our own tooling technology in the process.”