Grinding of PCD - Analysis of wear mechanisms during PCD grinding with ceramic bonded diamond grinding wheels on the basis of a friction model

 

Economical processing of fibre-reinforced plastics, titanium alloys or aluminium alloys containing silicon is often only possible with polycritical diamond cutting materials (PCD cutting materials). PCD tools are often shaped by grinding. However, the high hardness of PCD results in high grinding wheel wear and long machining times. The PCD grinding process could be significantly improved by increasing productivity and reducing grinding wheel wear. This requires knowledge of the thermal and mechanical loads in the grinding process and their effect on the cutting and removal mechanisms as well as on grinding wheel wear in order to design the grinding process in a targeted manner from an economic point of view.

On the basis of grinding tests, the existing thermal and mechanical process loads during PCD grinding and the resulting workpiece edge zones are analysed. On the basis of the knowledge gained, cause-effect relationships can be formulated which explain the predominant machining and stock removal mechanisms in the grinding of PCD materials as a function of the predominant process parameters.

The overall objective of the project is to develop a parameter-dependent friction model which allows a prediction of the mechanical and thermal process load for the grinding of different PCD materials with different grinding wheel specifications and variable process parameters.