How do manufacturers control the shape and strength of synthetic abrasive grains?

Manufacturers control the shape and strength of abrasive grains primarily through the crushing process. By adjusting the intensity of the crushing pressure, producers can tailor the physical characteristics of the grains to suit specific industrial applications.1

• Splintery and Sharp Grains: Applying heavy crushing pressures tends to produce grains that are splintery, sharp, and relatively weak. These grains are highly effective for coated abrasive products because they penetrate materials easily and their cutting edges break down readily, which facilitates self-resharpening.1
• Regular and Strong Grains: When the intended use involves grinding large amounts of material under heavy pressure—such as with a grinding wheel—manufacturers aim for a more regular, robust shape. These stronger grains are designed to withstand high forces, as the heavy pressure itself ensures sufficient penetration into the workpiece, making extreme sharpness less critical for performance.1

Once crushed, the grains are sorted by size using test screens for coarser grits or through sedimentation tests for finer powders to ensure consistency in the final product.1