Experimental Investigation On Grinding Engineering Ceramics With Brazed Diamond Abrasive Wheel

All around the world, the grains of brazed monolayer diamond tools are mostly 40/50 mesh, which are used to coarsely machining hard brittle materials such as stone industry field. This papers focus on development of brazed monolayer 140/170 mesh diamond grinding wheels used to grind engineering ceramics, dressing the uniform grain height and arrangement of grains.The main creative contents in this paper are as follows:1) A new segmented grinding wheel of the brazed monolayer diamond was developed with a defined grains pattern on the wheel surface. It includes the process of high temperature vacuum brazing, which include the secondary soldering and brazing processes, grain arrangement.2) There are some effective methods to choose to improve the rotational accuracy of grinding wheel. The physical sieving method was used to optimize the size distribution of Diamond abrasive particle. Grinding experiments on 45 steel segment workpieces were carried out to decrease radial jumpiness with green carborundum grinding wheel pre-brazing. Brazing layer was dressed for a higher spindle of the hub before brazed diamond. Moreover, brazed diamond wheels with defined distribution patterns was conditioned by touch-dressing method so that grit tips get micro-conditioned and allow the underlying grits to participate and consequently improve the quality of finish.3) Results of grinding zirconia using brazed segmented diamond wheel were presented. The experiment results showed that the grinding forces ratio becomes higher with the increasing of the specific material removal rate and the specific energy falls with the maximum undeformed chip thickness removal rate during grinding zirconia process. All the ground surfaces of zirconia were generated by the combined removal modes of brittle and ductile. Furthermore, the grits of the brazed diamond grinding wheel failed mainly in attritious wear modes other than pull-out ones in conventional electroplated and sintered diamond tools. The work accomplished in this paper, to a certain extent, not only succeeded to process advantages of brazed monolayer 40/50 mesh diamond grinding wheels, but also improved grinding accuracy, broaden the applications of brazed monolayer diamond tools and contributed to further develop precision brazed diamond tools.