Increasing the efficiency of the grinding process of polycrystalline superhard materials with diamond wheels on organic and metal bonds
DOI:
https://doi.org/10.31471/1993-9965-2026-1(60)-88-93Keywords:
polycrystalline superhard materials, grinding process, diamond wheel, wheel bond, working surface of the wheel, wheel self-sharpening mechanism, grinding method, initial processing parameters, grinding process modeling, stress-strain stateAbstract
The paper considers the specifics of self-sharpening of diamond grinding wheels made on organic and metal bonds during the processing of polycrystalline superhard materials (PSHM). Traditional processing methods face significant difficulties due to the comparable hardness of the tool and the processed material, which leads to intensive wear of diamond grains and the transition of the grinding process to a friction mode. The theoretical statement is justified that the interaction of materials with comparable hardness forms special conditions for the implementation of the self-sharpening mechanism of the diamond-bearing layer, which differs from classical ideas about abrasive destruction. For the first time, the periodic nature of the self-sharpening process was experi-mentally revealed and its physical nature was determined based on studies of processing synthetic polycrystalline diamonds of the ASB brand with 12A2-45 type wheels. It is shown that the decisive factor of this phenomenon is the dynamic power tension in the contact zone. It is justified that the presence of periodicity indicates potential reserves for increasing the efficiency of the grinding process. To stabilize the process and ensure a constant cutting ability of the wheel on a metal bond, the use of a special electrochemical relief control device is proposed, which automatically maintains the optimal height of grain protrusion. It is proved that this approach allows reducing diamond consumption by 10-15% and improving the quality of the processed surface. The features of self-sharpening of wheels on organic bonds are also analyzed, where the elastic deformation of the bond contributes to the appearance of microcracks in the grains and the formation of new cutting edges. Based on the obtained results, ways for further optimization of the grinding process using modern methods of 3D modeling of the stress-strain state in the cutting zone are determined.
Downloads
References
1. McNamara, D., Alveen, P., Carolan, D., Murphy, N., Ivanković, A. Fracture toughness evaluation of polycrystalline diamond as a function of microstructure. Engineering Fracture Mechanics, 2015, Vol. 143, pp. 1–16. https://doi.org/10.1016/j.engfracmech.2015.06.008
2. Schwander, M., Partes, K. A review of diamond synthesis by CVD processes. Diamond & Related Materials, 2011, 20(9):1287–1301. https://doi.org/10.1016/j.diamond.2011.08.005
3. Bergs T. Tribological conditions in grinding of polycrystalline diamond. Diamond & Related Materials, 2020. https://doi.org/10.1016/j.diamond.2020.108971
4. Lu Y., Wang B., Rosenkranz A. et al. Nanoscale smooth and damage-free polycrystalline diamond surface ground by coarse diamond grinding wheel. Diamond & Related Materials, 2022. https://doi.org/10.1016/j.diamond.2022.108971
5. Kundrák, J., Fedorenko, D.O. Fedorovich, V. О., Fedorenko, E.Y., & Ostroverkh, E.V. Porous diamond grinding wheels on ceramic binders: Design and manufacturing. Manufacturing Technology, 2019, Vol. 19, No. 3, pp. 446–454. https://doi.org/10.21062/ujep/311.2019/a/1213-2489/MT/19/3/446
6. Li, H., & Chen, X. (2023). Wear characteristics and self-sharpening mechanism of micro-grooved diamond grinding wheel for optical glass. Journal of Manufacturing Processes, 101, 796-808. https://doi.org/10.1016/j.jmapro.2023.07.067
7. Wang, F., Liu, Y., & Zhao, Q. (2024). Advanced grinding technology for polycrystalline diamond: A review on mechanisms and wheel topography. Tribology International, 193, 109312. https://doi.org/10.1016/j.triboint.2024.109312
8. Grabchenko A.I., Dobroskok V.L., & Fedorovich V.A. (2006). 3D modeling of diamond-abrasive tools and grinding processes. Kharkiv: NTU "KhPI". 364 p.
9. Kundrák, J., Fedorovich, V., Markopoulos, A. P., Pyzhov, I., & Kryukova, N. (2016). Diamond grinding wheels production study with the use of the finite element method. Journal of Advanced Research, 7(6), 1057–1064. https://doi.org/10.1016/j.jare.2016.08.003
10. Kundrák, J., Fedorovich, V., Markopoulos, A. P., Pyzhov, I., & Ostroverkh, Y. (2022). Theoretical Assessment of the Role of Bond Material during Grinding of Superhard Materials with Diamond Wheels. Machines (MDPI), 10(7), 543. https://doi.org/10.3390/machines10070543
11. Xu, L., et al. (2023). Fabrication and Polishing Performance of Diamond Self-Sharpening Gel Disc. Micromachines, 15(1), 56. https://doi.org/10.3390/mi15010056
12. Gołąbczak, M., Gołąbczak, A., & Tomczyk, B. (2021). Electrochemical and X-ray Examinations of Erosion Products during Dressing of Superhard Grinding Wheels Using Alternating Current and Ecological Electrolytes of Low Concentration of Chemical Compounds. Materials, 14(6), 1375. https://doi.org/10.3390/ma14061375
13. Zhou, L., Morgan, M. N., & Lin, C. (2022). An investigation of the grinding characteristics of polycrystalline diamond (PCD) tools. Journal of Manufacturing Science and Engineering, 144(5), 051009. https://doi.org/10.1115/1.4052345
14. Kovalenko, V., Kopecký, L., & Píška, M. (2022). Wear mechanisms of diamond grains in grinding wheels with organic bonds when grinding PCD. Materials, 15(13), 4658. https://doi.org/10.3390/ma15134658
15. Mamalis, A.G., Grabchenko, A.I., Fedorovich, V.A., & Kundrák, J. (2009). Methodology of 3D simulation of processes in technology of diamond-composite materials. Int. J. Adv. Manuf. Technol., 43(11–12), 1235–1250. https://doi.org/10.1007/s00170-008-1802-0
Downloads
Published
How to Cite
Issue
Section
License
Авторські права....
1.png)
