Design And Manufacturing Of Porous Metal-bonded Diamond Grinding Wheel

Along with the continuous advancement of computer aided design technologies, numerical simulation has become a major tool for designing and studying the materials mechanical behaviors. In this paper, material properties of the segment of the porous metal-bonded diamond grinding wheel were researched by finite element simulation. Segments were manufactured according to the design result and their elastic modulus was measured.The key points are as follows:The influence of the porosity on the elastic modulus was analyzed through a finite element method. In the FEM model, the design variable only includes the porosity, and the tetrakaidecahedron model is applied as the microstructure model of porous metal matrix. The corresponding porosity was decided in order to meet the requirement of the elastic modulus.Based on the theory of microstructural mechanics and design of composite materials, micro-mechanics finite element method is used to design porous metal-bonded diamond grinding segment. In the model, the only design variable is the diamond concentration. A concentration range of diamond that can meet the required elastic modulus is calculated.A series of porous metallic matrix with various porosity and good shapes were manufactured through adjusting the partitioning among Ni-Cr filler, high temperature solid grains and foamer by loose powder sintering. The elastic modulus of the matrix was measured. Then diamond grains are added in the form of reinforcement to fabricate porous metal-bonded diamond grinding wheel segment with different concentrations, and their elastic modulus are also measured.The designed and measured values are compared to verify the validity of the design and to analyze something that needs to be further improved.