With many years’ experience in machining cast materials, Tyrolit has developed first-class grinding solutions in this field and raised quality to a new level.
Grinding cast iron, cutting off sprues, grinding off the casting skin — the finishing of castings places particular demands on tools: cast materials are abrasive, the surfaces are often uneven, and the operational pressure in foundries is high. For over 100 years, Tyrolit has been developing grinding and cutting tools specifically for the foundry industry and, with its product range, covers every stage of castings processing — from manual freehand grinding right through to fully automated robotic applications. The majority of the products are in the PREMIUM segment and guarantee a long service life, consistently high cutting performance and the highest levels of workplace safety. Worldwide, 100 megatonnes of castings are produced each year — Tyrolit supplies foundries in 65 countries with tailored solutions.
The choice of process depends on the workpiece size, quantity and required surface quality. In the case of freehand grinding the angle grinder is used with roughing discs (Ø 115–230 mm) or cutting discs — offering flexibility for small production runs and varying component geometries. When pedestal and pendulum grinding the workpiece is fed manually into the stationary machine, or the grinding wheel moves over the cast component in both synchronous and counter-rotating motions — particularly cost-effective for heavy and bulky cast components. In the automatic fettling In these applications, grinding machines and industrial robots carry out the machining; here, Tyrolit relies on resin-bonded grinding wheels and diamond cutting discs, which ensure maximum service life and absolute precision when working with grey and ductile cast iron. For deburring and work in hard-to-reach areas, grinding pins and carbide burrs for straight grinders are also available.
For machining grey cast iron (GJL) and ductile cast iron (GJS), Tyrolit offers specially tailored roughing discs in diameters of 178 and 230 mm. The CERABOND X roughing discs for cast iron with ceramic grain (CA) deliver maximum aggressiveness and consistent cutting performance — even under high contact pressure on the most challenging cast surfaces; they are optimised for high-frequency and pneumatic turbine angle grinders. The STANDARD and VIBSTAR SOFT roughing discs for cast iron are manufactured using high-quality zirconium corundum (ZA) and, depending on the degree of hardness, offer short grinding times, high stock removal rates and a long service life. For Cast steel CERABOND X products are also suitable for these applications, as they enable comfortable working with minimal effort. When castings with heavy sand inclusions the silicon carbide (C) cutting disc is the right choice — specially developed for this application.
Not every part of a cast component can be reached with disc tools. For deburring, chamfering and edge rounding in hard-to-reach areas, Tyrolit supplies resin-bonded mounted points in a wide range of shapes (cylindrical, spherical, conical, etc.) and dimensions from 10 × 25 mm to 50 × 25 mm with a 6 mm shank. Recommended grit size for cast iron: A 36–46, hardness grades P (high aggressiveness), Q (universal) and S (long service life). Thanks to their resin-bonded composition, these grinding pins are vibration-damping and impact-resistant. Carbide burrs for cast iron, steel and stainless steel (Ø 3–16 mm, various shapes) can be used on straight grinders, pneumatic machines or industrial robots and, thanks to their specially developed cutting geometry, deliver maximum material removal whilst minimising heat build-up.
Daily castings cleaning with an angle grinder puts a strain on the body — particularly due to vibrations, which in the long term can lead to musculoskeletal disorders, neurological conditions and circulatory problems. Tyrolit addresses this problem with its patented VIBSTAR technology: A multi-layer disc construction with a permanently attached plastic flange reduces vibration by up to 50 per cent. The VIBSTAR SOFT roughing discs for cast iron combine this vibration damping with a zirconia-corundum bond tailored to GJL and GJS grades, enabling gentle yet efficient machining. Furthermore, thanks to their special design, selected discs also reduce noise levels — a key consideration in noisy foundry environments.
Conventional grinding and cutting discs are cost-effective and tried-and-tested for many castings finishing tasks. However, as soon as large quantities are processed in automated production or the workpieces are made of hard grey or ductile cast iron, the use of diamond tools pays off. Tyrolit offers the FOCUR SA diamond cutting disc a specialised tool for automatic castings deburring on grey and ductile cast iron, which impresses with its exceptionally long service life, clean cut quality and reduced noise and dust emissions. The CERABOND X cutting discs for cast iron (ceramic grain, Ø 178–230 mm) can also be used on very hard, demanding workpieces and guarantee maximum tool life and the fastest cutting times. Tyrolit application engineers provide advice on the optimal combination of diamond tools with conventional tools in automated processes.
Tyrolit is one of the world’s leading manufacturers of grinding and cutting tools for the foundry industry — the result of over 100 years’ experience and targeted research in this sector. For more than 20 years, Tyrolit has been a pioneer in the use of super-abrasives for the dry machining of grey and ductile cast iron. Today, foundries worldwide benefit from a comprehensive quality system, the highest safety standards in accordance with EN standards and oSa guidelines, as well as a dedicated team of application engineers who provide on-site support for process optimisation. The extensive range of over 80,000 standard products, fast delivery times and bespoke solutions make Tyrolit a reliable partner for every requirement in foundry machining.
