Tungsten carbide is the material of choice for high-performance cutting tools, dies, and wear parts—but its extreme hardness and brittleness make it notoriously difficult to grind. Achieving consistent results in grinding carbide tools requires not only the correct abrasive material but also the right bond type, wheel structure, and grinding parameters.
This guide provides engineers and operations managers with the technical framework needed to optimize performance when working with carbide. From selecting the right diamond grinding wheel for carbide to fine-tuning your process parameters, we’ll show you how to improve tool life, achieve superior surface finish, and minimize wear on both your tools and equipment.
Tungsten carbide is composed of hard carbide particles (WC) held together by a cobalt binder. Its high hardness (typically 1600–2000 HV) makes it extremely wear-resistant, but also very difficult to machine using conventional abrasives like silicon carbide abrasives or aluminum oxide wheels.
This is why diamond grinding wheels - which fall under the category of superabrasive wheels - are the industry standard for tungsten carbide grinding. Diamond, with its unmatched hardness, is the only abrasive capable of efficiently cutting and shaping carbide without rapid wheel degradation or thermal cracking.
Carbide’s brittleness makes it highly sensitive to thermal shock. Excessive grinding temperatures can cause:
To prevent this, selecting the right bond and maintaining optimal process conditions—especially coolant use—is critical to performance and tool longevity.
Resin bond diamond wheels are a top choice for finishing operations in carbide tool grinding, offering excellent results for grinding and sharpening. Their softer matrix offers and the wheels provide:
These wheels are ideal for:
The softer bond wears faster but exposes new sharp diamonds more readily, making it suitable for low to medium stock removal.
For roughing or profile grinding operations where wheel wear and form retention are critical, vitrified bond diamond wheels offer superior performance. These wheels feature:
Vitrified bonds are excellent in automated grinding setups and high-volume environments where maintaining tight tolerances is essential.
CBN (Cubic Boron Nitride) wheels are optimized for ferrous materials and are ineffective on tungsten carbide. Additionally, metal bond diamond wheels, while extremely durable, are often too hard and prone to excessive heat buildup and minimized diamond wheel wear when used on carbide tools—making them a poor fit unless specialized equipment and cooling systems are in place.
Wheel speed (surface feet per minute, or SFPM) and feed rate directly impact heat generation, wheel wear, and surface integrity. which are central to achieving optimal grinding performance. A balanced approach is key to higher grinding efficiency:
Typical grinding speeds for diamond wheels in carbide applications range from 4000 to 6000 SFPM, depending on wheel diameter, grit size, and coolant availability.
Coolant use is ideal when grinding carbide tools. Proper coolant delivery:
Shallow, incremental passes also help manage heat and protect the integrity of the cutting edge. A depth of cut between 0.001"–0.003" is typically recommended.
Diamond wheels require regular truing (restoring shape) and dressing (exposing fresh abrasive). Failure to maintain the wheel leads to:
Use appropriate dressing tools, such as silicon carbide sticks or rotary diamond dressers, depending on wheel bond type and machine setup.
Each grinding task places different demands on the wheel:
By matching wheel bond, grit size, and structure to the task, you ensure optimal edge quality, part consistency, and tool durability.
The grinding wheel is only part of the equation. Consistency in tungsten carbide grinding depends on:
This integrated approach ensures that both machine and wheel are performing at their peak.
Stat Reminder: Research confirms that for grinding tungsten carbide tools, the maximum allowed radial wear (Δr) of the grinding wheel is 30 μm (micrometers).
Source: ResearchGate
Maintaining your grinding wheels within this wear limit is critical for tool geometry and production repeatability.
Optimizing performance in grinding carbide tools comes down to choosing the right diamond grinding wheel, understanding how bond type influences results, and fine-tuning your grinding parameters to match the application.
Eagle Superabrasives is an industry leader in manufacturing custom diamond grinding wheels for carbide. Whether you’re roughing, finishing, or profile grinding, we’ll help you select the best bond, structure, and grit for your specific application—ensuring consistent performance, maximum wheel life, and superior surface finish.
Have questions about your grinding process? Contact Eagle Superabrasives to speak with an expert and get custom recommendations for your carbide grinding operations.
Diamond wheels are best for grinding carbide and composites; CBN suits hardened steels. For carbide, vitrified diamond or superabrasive wheel provides better surface and wear resistance.
Vitrified bond wheels offer high grinding performance, cooler grinding zone, and consistent wear resistance; resin bonds give different finishing and are used for specific grinding and sharpening.
Dry grinding carbide is possible with proper grinding pressure, diamond wheel wear control, and suitable wheel; CNC grinding setups often enable high-performance dry grinding.
Use lower grinding pressure, appropriate wheel type, fine superabrasive grit, stable CNC grinding feeds and optimal grinding speeds for grinding intricate profiles.
Diamond wheels are widely used for carbide and show excellent wear resistance; CBN excels on steels. Both wheels provide higher grinding performance when matched to material.
Precision grinding machines and CNC grinding with vitrified diamond or continental diamond tool wheels are suitable for grinding of carbide and grinding and sharpening of cutting edges.