DFG grain coating

Grinding processes are among the key technologies in high-precision manufacturing. The tools used in these processes must withstand intense thermal and mechanical stresses—especially at the interface between the abrasive grain and the bond. This zone has a significant influence on the grain retention force and thus on wear behavior at the microscopic level as well as on the cutting ability of the tools. In practice, failure mechanisms such as grain breakage often lead to reduced service life.

The project systematically investigates the influence of different grain coatings on the performance of metal-bonded grinding wheels. The focus is on diamond grains coated with different metallic layers, such as nickel, titanium, or copper. These coatings are intended to create a material bond between the grain and the bond, thereby improving grain retention and thermal conductivity.

Objectives

The aim of the project is to specifically optimize the interface properties between diamond grains and the bond in metal-bonded grinding wheels. Through systematic investigation of the influence of different coatings, layer thicknesses, and bond compositions, the grain retention force, thermal conductivity, and service life of the tools are to be significantly improved. Based on the mechanisms developed, new grinding tools with increased performance will be developed.

Benefits

• Increased tool life through improved grit retention and reduced wear
• More efficient grinding processes through optimized heat dissipation

Approach

The project investigates the interactions between diamond grains, bonding, and various metallic coatings in order to understand their influence on the properties of the interface. To this end, the type of coating, layer thickness, grain size, and bonding composition are varied, and the coatings are characterized prior to sintering. This is followed by tests with different sintering parameters, bending fracture tests, SEM, FIB, and EDX analyses, and thermal conductivity measurements. Finally, single-grain grinding and grinding tests are carried out to evaluate wear behavior and workpiece quality.

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Contact Maren Friedrich  via email at friedrich@ifw.uni.hannover.de or by phone at +49 511 762 18251.