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[sealdaddy]

Being even a bit "too aggressive" with pressure in early stages causes fractures deeper in the material than will polish out, right?

Any suggestions?

[lithicbeads]

It can. When I was production cutting I used a trick that no one likes to hear. I used a worn steel 600 grit wheel before any sanding. The 600 was still aggressive enough to cut out the deep gouges left from the 100 grit steel wheel. The benefits were very evident on expensive crystal based rough where there is enough translucency to really gague the frosting effect of the coarse grits. With less expensive stones I just use a slightly thicker preform and sand more.

[bgast1]

This is an interesting topic to me, I will be looking to see what might develop from it. 

[Itsandbits]

I sure found that out cutting the sillimanite with Kyanite; the kyanite shatters on the 100 grit wheel when you're too aggressive

[sealdaddy]

In my "newbiness" on this subject, it seems to depend on the different density and fracture structures of various materials.
My feeling now is that if I ever use my 100 grit diamond hardwheel again, I an going to use it lightly. I think I'd rathe not be in such a hurry, and use a less course git, a bit longer.