Dry electrical discharge dressing and truing of diamond grinding wheel V-tip for micro-grinding
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2017-01-01 |
| Authors | Yanjun Lu, L. J. Li, Jin Xie, Chilou Zhou, Rui Guo |
| Institutions | South China University of Technology |
| Citations | 3 |
| Analysis | Full AI Review Included |
Technical Analysis: Dry ECD Truing of Diamond Grinding Wheels for Micro-Grinding
Section titled âTechnical Analysis: Dry ECD Truing of Diamond Grinding Wheels for Micro-GrindingâThis documentation analyzes the research into high-precision dry electro-contact discharge (ECD) truing of diamond grinding wheel V-tips. The findings are highly relevant to engineers focused on ultraprecision machining, tool fabrication, and material processing of hard and brittle materials. 6CCVDâs portfolio of high-purity MPCVD diamond materials is ideally suited to replicate and advance this cutting-edge research.
Executive Summary
Section titled âExecutive SummaryâThe following points summarize the core technical achievement and its implications for ultraprecision manufacturing using diamond tooling:
- Novel Methodology: Proposed and validated a high-efficiency dry ECD truing technique for shaping V-tip profiles on metal-bonded diamond grinding wheels.
- Precision Truing Achieved: The process successfully created a sharp V-tip profile, achieving a minimum V-tip angle error of 1.1° and a minimum radius of 33 ”m.
- Optimal Process Parameters: Identified the critical optimal pulse discharge parameters for maximizing V-tip accuracy: Open-Circuit Voltage E = 5V, Pulse Frequency f = 4000Hz, and Duty Cycle dc = 50%.
- Validation of Output Quality: The trued V-tip wheel successfully fabricated regular, smooth micro-groove, and micro-pyramid array structures on difficult-to-cut materials (microcrystallite glass ceramics, Al/SiCp composites).
- Material Necessity: The research underscores the need for high-purity, structurally robust diamond substrates (such as 6CCVDâs SCD or PCD) to withstand high-frequency ECD processes and maintain geometric integrity for ultra-precision tooling.
- 6CCVD Relevance: 6CCVD supplies the foundational SCD and PCD materials required for manufacturing the next generation of precision diamond tools, offering customization in thickness, geometry, and metalization crucial for integration into advanced ECD/EDM systems.
Technical Specifications
Section titled âTechnical SpecificationsâThe following critical data points were extracted from the analysis of the dry ECD truing process and performance metrics.
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Optimal Open-Circuit Voltage (E) | 5 | V | Dry ECD Truing Condition |
| Optimal Pulse Frequency (f) | 4000 | Hz | Dry ECD Truing Condition |
| Optimal Duty Cycle (dc) | 50 | % | Dry ECD Truing Condition |
| Minimum V-Tip Angle Error | 1.1 | ° | Achieved on SD600 Wheel |
| Minimum V-Tip Radius (rv) | 33 | ”m | Achieved at Optimal Parameters |
| Grinding Wheel Diameter (D) | 160 | mm | SD600 Diamond Wheel |
| Grinding Wheel Width (B) | 2 | mm | SD600 Diamond Wheel |
| ECD Truing Depth of Cut (a) Range | 1 - 10 | ”m | Per Pass |
| Truing Wheel Speed (vw) Range | 12.6 - 20.9 | m/s | ECD Process Parameter |
| Workpiece Materials (Tested) | Microcrystallite Glass Ceramics; SiC Reinforced Al (Al/SiCp) | N/A | Validation Substrates |
Key Methodologies
Section titled âKey MethodologiesâThe V-tip profile of the diamond grinding wheel was formed and optimized through a dry Electro-Contact Discharge (ECD) truing and dressing procedure:
- Grinding Wheel Setup: A metal-bonded SD600 diamond grinding wheel (D=160 mm, B=2 mm) was mounted on a SMART B818 CNC grinder.
- Electrode Configuration: A hybrid electrode composed of Copper (Cu) and Silicon Carbide (SiC, #600) (Size: 20Ă50Ă15 mm) was used.
- Discharge Mechanism: The pulse power supply was connected between the hybrid electrode and the conductive metal bond of the diamond wheel. Electric sparks were produced when the rotary diamond wheel cut the conductive electrode (rolled Cu chip).
- Truing Path: The diamond wheel was driven along a pre-set crossed V-shape interpolation path to gradually form the V-tip profile.
- Parameter Variation: Open-circuit voltage (E=10-25V), pulse frequency (f=1000-5000Hz), and duty cycle (dc=10-50%) were varied systematically to determine the optimal settings that minimize V-tip angle error and radius.
- Tool Validation: The trued wheel was used for micro-grinding two hard materials: microcrystallite glass ceramics and Al/SiCp composites, fabricating micro-groove and micro-pyramid array structures.
- Machining Speeds: Rough machining feed speed vf=600 mm/min; Finish machining feed speed vf=300 mm/min.
6CCVD Solutions & Capabilities (Material Science for Ultraprecision Truing)
Section titled â6CCVD Solutions & Capabilities (Material Science for Ultraprecision Truing)âThe high-precision ECD truing methodology described requires diamond materials with exceptional structural uniformity and purity to ensure sharp, consistent cutting edges. 6CCVD is an ideal partner for supplying the base materials necessary for next-generation diamond micro-tools.
Applicable Materials
Section titled âApplicable MaterialsâTo achieve the stringent geometry and surface quality (sub-micron features) required for this V-tip application, 6CCVD recommends materials optimized for extreme mechanical stability and polishability:
| 6CCVD Material | Application Suitability | Key Advantages |
|---|---|---|
| High-Purity Single Crystal Diamond (SCD) | Ideal for precision inserts and critical tool edges where the V-tip geometry (33 ”m radius) must be maintained perfectly. | Near-zero defects, highest thermal stability, polishability down to Ra < 1nm, essential for ultra-sharp micro-tools. |
| Polycrystalline Diamond (PCD) - Fine Grain | Suitable for large-format grinding wheel segments and wear parts requiring high dimensional stability in metal bonding/ECD environments. | Available in large plates (up to 125mm), highly resistant to brittle fracture, superior wear resistance. |
| Boron-Doped Diamond (BDD) | Potential for future iterations where the diamond material itself acts as an electrode, enhancing the ECD process efficiency. | Excellent electrical conductivity, high corrosion resistance in electrolytic processes. |
Customization Potential
Section titled âCustomization PotentialâThe success of the ECD truing process relies on precise material geometry and integration. 6CCVDâs in-house capabilities directly address the material needs of this research:
- Custom Dimensions and Geometry: 6CCVD provides SCD and PCD plates/wafers with custom dimensions and specialized laser cutting services, allowing engineers to define the pre-form shape of the V-tip insert or abrasive segment with high accuracy before metal bonding or truing.
- Thickness Control: We offer precise thickness control for both SCD (0.1”m - 500”m) and PCD (0.1”m - 500”m), ensuring optimal material volume for tool longevity and efficient dressing.
- Advanced Metalization Services: As the dry ECD technique relies on electrical discharge, precise electrical contact is critical. 6CCVD offers in-house metalization (including Ti, Pt, Au, Pd) which can be applied to SCD or PCD surfaces to enhance bonding strength or facilitate specific electrode characteristics for optimized ECD performance.
- Ultra-low Roughness Polishing: To replicate the sharp cutting edges formed during ECD dressing, 6CCVD can pre-polish SCD materials to Ra < 1nm, establishing a superior starting surface for micro-tool fabrication.
Engineering Support
Section titled âEngineering Supportâ6CCVDâs dedicated team of PhD material scientists provides consultative support for projects involving extreme tolerances. We assist researchers in optimizing diamond selection based on:
- Truing Method Compatibility: Selecting materials best suited for high-frequency electro-discharge processes (ECD/EDM).
- Geometry Requirements: Tailoring crystal orientation (for SCD) or grain size (for PCD) to maximize stability for feature sizes down to the 33 ”m radius achieved in this study.
- Application Environment: Ensuring the material chosen performs optimally when grinding hard and brittle composites like SiC reinforced Al (Al/SiCp).
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.
View Original Abstract
The dry electrical discharge dressing and truing technology was proposed to realize the high efficient and precise truing of diamond grinding wheel in this paper.Firstly, the V-shape tip of diamond grinding wheel was formed using dry electro-contact discharge (ECD) truing along setting crossed V-shape interpolation path.Secondly, the influence of different pulse discharge parameters on V-tip angle and V-tip radius was investigated, respectively.Finally, the trued V-tip diamond wheel was employed to fabricate micro-groove and micro-pyramid array structures on the surfaces of two hard and brittle materials by micro-grinding machining.The results indicated that the optimal pulse discharge parameters were open-circuit voltage E of 5V, pulse frequency f of 4000Hz and duty cycle d c of 50%.The least V-tip angle error and radius of trued SD600 V-tip diamond grinding wheel was 1.1Âș and 33 ”m, respectively.The micro-groove and micro-pyramid structures with regular shape and smooth surface can was effectively machined on the surfaces of difficult-to-cut materials.