Home / News & Blog / Abrasive Blog / Why Is My Abrasive Grain Not Performing? Common Issues and How to Fix Them?
By Leif Shi – 20+ Years in Abrasives Manufacturing
If you’ve ever wondered why your abrasive grains aren’t cutting like they used to—or worse, failing altogether—you’re not alone. As a technical consultant and engineer in the abrasives industry for over two decades, I’ve helped countless manufacturers troubleshoot grain performance problems that lead to costly downtime, poor finishes, and wasted materials.
In this article, we’ll explore the most common reasons abrasive grains underperform—and how to fix them fast.
What’s happening?
Your abrasive grains lose their sharpness quickly, leading to poor cutting performance, excessive heat, and glazing on the workpiece.
Why it happens:
Using the wrong type of grain for the material (e.g., brown fused alumina on high-alloy steel);
Improper grit size—too fine for a heavy stock removal job;
Excessive pressure causing grain flattening instead of fracturing;
How To Fix it:
✅ Switch to a tougher or self-sharpening grain like ceramic alumina or zirconia alumina for demanding materials.
✅ Use a coarser grit size for more aggressive cutting.
✅ Let the abrasive do the work—apply moderate pressure to allow micro-fracturing.
What’s happening?
The finished surface is rougher than expected, with chatter marks or scratches that weren’t there before.
Why it happens:
Coarse grit size used for finishing
Grain breakdown is too fast, leading to inconsistent cutting
Uneven distribution of abrasive on coated tools (like belts or discs)
How To Fix it:
✅ For fine finishing, choose F80–F220 grit brown fused alumina or even switch to white fused alumina for smoother results.
✅ Check backing flexibility and bonding consistency if using coated abrasives.
✅ Upgrade to precision-graded abrasives for tighter grit control.
What’s happening?
The abrasive tool becomes gummed up, especially when grinding softer metals, aluminum, or non-metallic materials.
Why it happens:
Grit size is too fine;
No anti-loading treatment on the surface;
Working with materials that smear rather than chip;
How To Fix it:
✅ Use coarser grain (F24–F36) to provide better chip clearance.
✅ Choose abrasives with anti-loading coatings or stearates.
✅ For woodworking or aluminum, try open-coat abrasives to reduce clogging.
What’s happening?
Your abrasive grains or tools wear out much faster than expected, sometimes unevenly across the surface.
Why it happens:
Poor-quality grains with inconsistent hardness;
Incorrect bonding process or density;
Misalignment in tool setup (like belt tracking or wheel balance);
How To Fix it:
✅ Always source abrasives from ISO-certified manufacturers with strict QC (like DOMILL).
✅ Match grain hardness and shape to the job—blocky grains are more durable, sharp grains cut faster but wear out quicker.
✅ Check your machine settings for vibration or speed inconsistencies.
What’s happening?
Your abrasive tool works great for one batch, then suddenly underperforms in the next—same machine, same material.
Why it happens:
Variability in grain quality (especially in bulk purchases);
Inconsistent shape, density, or impurity content;
Inadequate inspection or quality control from the supplier;
How ToFix it:
✅ Ask your supplier for test reports on grain chemical composition and magnetic matter.
✅ Ensure they use a shaping line or Barmac system for consistent grain structure.
✅ DOMILL abrasive grains, for example, are air-washed, low-impurity, and tightly graded for batch-to-batch stability.
In my 20+ years working with grinding wheel manufacturers, sandpaper converters, and surface prep companies, I’ve seen this one pattern: Choosing the right grain isn’t about what’s cheapest—it’s about what works.
The right abrasive grain is like a well-matched tool in your hand. If your current one isn’t doing the job, don’t just live with it—optimize it.
If you’re facing ongoing issues with abrasive grain performance, feel free to reach out. I’m always happy to share insights or provide free samples from DOMILL to help you test the difference.
