ELID Assisted Precision Conditioning of Coarse-Grained Diamond Grinding Wheel

In order to realize ductile machining of optical glasses using mono-layer nickel electroplated coarse-grained diamond grinding wheel, a novel conditioning technique features using a copper bonded diamond grinding wheels of 15m grain size dressed by ELID (electrolytic inprocess dressing) to condition the 46m grain sized diamond wheel has been developed. During the conditioning process, a force transducer was used to monitor the conditioning force, a coaxial optical distance measurement system was used to in-situ monitor the modified wheel surface status. White-light interferometry (WLI), scanning electron microscopy (SEM) and atomic force microscopy (AFM) were used to characterize the conditioned wheel surface status as well as the ground optical glass surface topography correspondingly. The experimental result indicates that a minimized wheel radial run-out error of less than 2μm as well as the top-flattened diamond grains of constant wheel peripheral envelop profile were generated on a 5-axis ultra-precision machine tool. The grinding experiment proved that the well conditioned 46μm coarse-grained diamond wheel can be used in realizing the ductile grinding of optical glass BK7, which indicates that the newly developed conditioning technique is feasible and applicable to introduce the coarse-grained diamond wheels into precision machining of brittle and hard-to-machine materials.

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Fabrication of Diamond Micro Tool Array (DMTA) for Ultra-Precision Machining of Brittle Materials

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.329.737 ◽

2007 ◽

Vol 329 ◽

pp. 737-742 ◽

Cited By ~ 3

Author(s):

Qing Liang Zhao ◽

Da Gang Xie ◽

Ekkard Brinksmeier ◽

Otmann Riemer ◽

Kai Rickens

Keyword(s):

Grain Size ◽

Brittle Materials ◽

Force Transducer ◽

Coarse Grained ◽

Experimental Result ◽

Grinding Wheel ◽

Diamond Grinding ◽

Ductile Machining ◽

Wheel Topography ◽

Micro Tool

A novel conditioning technique to precisely and effectively condition the nickel electroplated mono-layer coarse-grained diamond grinding wheel of 91m grain size was developed to fabricate a Diamond Micro Tool Array (DMTA) in ductile machining of brittle materials. During the fabricating process, a copper bonded diamond grinding wheels (91m grain size) dressed by ELID (electrolytic in-process dressing) was applied as a conditioner, a force transducer was used to monitor the conditioning force, and a coaxial optical distance measurement system was used to insitu monitor the modified wheel surface status. The experimental result indicates that the newly developed conditioning technique is applicable and feasible to generate required wheel topography of less than 2μm run-out error and grain geometries. The taper cutting test on BK7 proves the fabricated DMTA is capable of realizing ductile machining of brittle materials.

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Ultraprecision Ductile Grinding of Optical Glass Using Super Abrasive Diamond Wheel

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.339.382 ◽

2007 ◽

Vol 339 ◽

pp. 382-388 ◽

Cited By ~ 2

Author(s):

Qing Liang Zhao ◽

Ekkard Brinksmeier ◽

Otmann Riemer ◽

Kai Rickens

Keyword(s):

Grain Size ◽

Optical Glass ◽

Diamond Wheel ◽

Force Transducer ◽

Coarse Grained ◽

Experimental Result ◽

Grinding Wheels ◽

Diamond Grinding ◽

Ductile Grinding ◽

Diamond Grain

In this paper, a novel conditioning technique features using copper bonded diamond grinding wheels of 91μm grain size assisted with ELID (electrolytic in-process dressing) as a conditioner to precisely and effectively condition nickel electroplated monolayer coarse-grained diamond grinding wheels of 151μm grain size was firstly developed. Under optimised conditioning parameters, the super abrasive diamond wheel was well conditioned in terms of a minimized run-out error and flattened diamond grain surfaces of constant peripheral envelope, with the conditioning force monitored by a force transducer as well as the modified wheel surface status in-situ monitored by a coaxial optical distance measurement system. Finally the grinding experiment on BK7 was conducted using the well conditioned wheel with the corresponding surface morphology and subsurface damage measured by AFM (atomic force microscope) and SEM (scanning electron microscope) respectively. The experimental result shows that the newly developed conditioning technique is applicable and feasible to ductile grinding optical glass featuring nano scale surface roughness, indicating a prospect of introducing super abrasive diamond wheels into ductile machining of brittle materials.

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Experimental Study on Performance of Monolayer Brazed Diamond Wheel through Chemical-Mechanical Dressing

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.325.208 ◽

2011 ◽

Vol 325 ◽

pp. 208-212 ◽

Cited By ~ 5

Author(s):

Hong Hua Su ◽

Jiu Hua Xu ◽

Yu Can Fu ◽

Wen Feng Ding ◽

Shuai Wang

Keyword(s):

Optical Glass ◽

Ground Surface ◽

Diamond Wheel ◽

Substantial Improvement ◽

Grinding Wheel ◽

Dressing Method ◽

Diamond Grinding Wheel ◽

Diamond Grinding ◽

Before And After ◽

Ground Surface Roughness

The dressing methods of monolayer diamond tool have recently been developed increasingly because a substantial improvement of the ground surface roughness could be achieved with the dressed monolayer diamond tools. In this paper, a new dressing method was proposed, namely chemical-mechanical dressing of the diamond grits. Dressing experiments were carried out on the monolayer brazed diamond grinding wheel. The grit-tip distances from the base of wheel substrate were measured before and after dressing. Grinding experiments were conducted on K9 optical glass after each dressing interval. The roughness parameters of the ground surfaces were measured. The outcome of this attempt appeared highly encouraging, and the dressing of monolayer brazed diamond grinding wheel is effective with the chemical-mechanical dressing.

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Characteristics of the Wheel Surface Topography in Ultra-precision Grinding of Silicon Wafers

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.389-390.36 ◽

2008 ◽

Vol 389-390 ◽

pp. 36-41

Author(s):

Feng Wei Huo ◽

Dong Ming Guo ◽

Ren Ke Kang ◽

Zhu Ji Jin

Keyword(s):

Surface Topography ◽

Sampling Interval ◽

Grinding Wheel ◽

Height Distribution ◽

Wheel Surface ◽

Diamond Grinding Wheel ◽

Diamond Grinding ◽

Cutting Surface ◽

Ultra Precision ◽

Cutting Direction

A 3D profiler based on scanning white light interferometry with a lateral sampling interval of 0.11μm was introduced to measure the surface topography of a #3000 diamond grinding wheel, and a large sampling area could be achieved by its stitching capability without compromising its lateral or vertical resolution. The protrusion height distribution of diamond grains and the static effective grain density of the grinding wheel were derived, and the wheel chatter and the deformation of the wheel were analyzed as well. The study shows that the grain protrusion height obeys an approximate normal distribution, the static effective grain density is much lower than the theoretical density, and only a small number of diamond grains are effective in the grinding process with fine diamond grinding wheel. There exists waviness on the grinding wheel surface parallel with the wheel cutting direction. The cutting surface of the grinding wheel is not flat but umbilicate, which indicates that the elastic deformation at the wheel edges is much larger than in the center region.

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Wear of Diamond Grinding Wheel during Low Speed Dressing by Alumina

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.658.120 ◽

2015 ◽

Vol 658 ◽

pp. 120-124

Author(s):

Tachai Luangvaranunt ◽

Natthawat Tangkaratanakul ◽

Patchanok Sakultantimetha

Keyword(s):

High Hardness ◽

Large Mass ◽

Diamond Wheel ◽

Grinding Wheel ◽

Work Piece ◽

Wheel Wear ◽

Diamond Grinding Wheel ◽

Diamond Grinding ◽

Dressing Tool ◽

Pin On Disk

Diamond grinding wheel is used in high precision grinding process, when work piece has a very high hardness. For a specific grinding interval, the wheel must be properly dressed, in order to remove swarf, sharpen the worn diamond grits, open up new diamond protrusions, and recondition the bond material. Dressing of diamond grinding wheel by alumina dressing tool has been simulated in a pin-on-disk machine in the research. Sharpening of the wheel is indicated by the increase of its roughness value, and surface microstructure with protruding sharp diamond grits. It was found that increasing of sliding distant from 100 to 500 m will increase the roughness of the wheel. The increase of contact load from 10 to 20 N will also increase roughness of the wheel, and the severity of wheel wear, indicated by high values of friction coefficient. A proper dressing of this nickel bonded SD1200 diamond wheel is by sliding against alumina dressing tool for at least 300 m under 10 N load. Sliding velocity has minimal effect to the results. A too large sliding distant and load will cause severe damage to wheel surface, and severe wheel wear, indicated by its large mass loss.

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A Study on Surface Generation of Metal-Bonded Diamond Grinding Wheel Dressed by Electro-Contact Discharge

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.304-305.76 ◽

2006 ◽

Vol 304-305 ◽

pp. 76-80 ◽

Cited By ~ 9

Author(s):

Jin Xie ◽

Yong Tang ◽

Junichi Tamaki

Keyword(s):

Ground Surface ◽

Open Circuit ◽

Surface Generation ◽

Grinding Wheel ◽

Wheel Surface ◽

Diamond Grinding Wheel ◽

Diamond Grinding ◽

Eds Analysis ◽

Fine Diamond ◽

Contact Discharge

This paper conducted Electro-Contact Discharge (ECD) dressing experiment for #600 diamond grinding wheel to understand how fine diamond grits protrude from metal-bonded wheel surface. The SEM observation, EDS analysis, image processing and 3D grit modeling on wheel surface were carried out to investigate grit protrusion characteristics. Then ECD dressing and mechanical dressing experiments were carried out to identify the effect of grit protrusion feature on grinding performance. It is confirmed that the dressed wheel surface topography is sensitive to open circuit voltage Ei, discharge polarity and electrode composition. Meanwhile, ECD dressing with Ei=15V and straight polarity can produce superior protrusion topography without the damage of diamond crystal faces and the bond tail behind protrusive grit. It can obtain better ground surface of hard-brittle material than mechanical dressing with the bond tail.

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Performance of Brazed Diamond Wheel in Grinding Cemented Carbide

Materials Science Forum ◽

10.4028/www.scientific.net/msf.532-533.381 ◽

2006 ◽

Vol 532-533 ◽

pp. 381-384 ◽

Cited By ~ 5

Author(s):

Shu Sheng Li ◽

Jiu Hua Xu ◽

Bing Xiao ◽

Ming Hua Yan ◽

Yu Can Fu ◽

...

Keyword(s):

Removal Rate ◽

Chip Thickness ◽

Diamond Wheel ◽

Surface Grinding ◽

Cemented Carbide ◽

Grinding Wheel ◽

Diamond Grinding Wheel ◽

Diamond Grinding ◽

Pull Out ◽

Wear Modes

A kind of brazed monolayer diamond grinding wheel was developed with a relatively regular distribution of grains on the wheel surface. Grinding performances of this kind of brazed wheel in the surface grinding of cemented carbide were studied. The experiment results show that the grinding forces ratio becomes higher with the increasing of the maximum undeformed chip thickness and the specific energy falls with the material removal rate during grinding cemented carbide process. Under certain grinding conditions, the material was removed almost through plastic deformation and good surface quality is gained. Furthermore, the grits of the brazed diamond grinding wheel fail mainly in attritious wear modes other than pull-out ones in conventional electroplated and sintered diamond tools, which indicates that the strong retention of brazing alloy to the diamond grits and longer service life of this kind of wheel.

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A Study on Fractal Dimension of Grit Protrusion Topography of Diamond Grinding Wheel

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.375-376.583 ◽

2008 ◽

Vol 375-376 ◽

pp. 583-587

Author(s):

Jin Xie ◽

Yu Guan Zhong

Keyword(s):

Image Processing ◽

Fractal Dimension ◽

Depth Of Cut ◽

Grinding Wheel ◽

Wheel Surface ◽

Diamond Grit ◽

Diamond Grinding Wheel ◽

Diamond Grinding

Fractal dimension is proposed to evaluate grit protrusion feature concerning grit protrusion area and length. The aim is to investigate crystal integrate of diamond grit protruded from grinding wheel after dressing. First, 3D crystal diamond grits are established in AutoCAD concerning various crystal configurations. Second, fractal dimension for original diamond grit is analyzed theoretically. Then, dressing experiment is carried out to investigate fractal dimension of grit protrusion topography by suing image processing of SEM photos of dressed grinding wheel surface. Finally, grit protrusion feature is investigated by fractal dimension concerning the depth of cut in dressing process. It is confirmed that fractal dimension can display grit protrusion feature and it may be used to evaluate dressing performance.

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