Investigations into the influence of the manufacturing process on the properties of vitrified-bonded diamond grinding wheels

Industrial users and manufacturers alike benefit from the results. In production, dressing cycles and non-productive times are reduced through targeted self-sharpening. Processes run more stably and reproducibly with less variation in force and quality. Workpiece roughness and dimensional accuracy improve, while scrap and rework are reduced. The service life increases with stable cutting performance and defined porosity and edge stability. In addition, parameterized guidelines for dressing and process start-up are created. Tool manufacturers receive a knowledge-based design instead of trial and error. This results in fewer prototypes and shorter development times, optimized sintering profiles and process windows with energy and cost advantages, as well as higher yields. Effect diagrams, regression and optimization models serve as quality and recipe guidelines, make products more robust against raw material fluctuations, and create reference data sets and test methods as a basis for standardization and customer-specific specifications.

Objectives

The aim of the project is the knowledge-based design of vitrified-bonded diamond grinding tools by quantifying the relationships between raw material properties, mixing transport and filling processes, pre-compaction and sintering, as well as the resulting grinding coating properties and application behavior. To this end, influencing factors are identified, effects along the process chain are recorded experimentally and mapped in effect diagrams, regression and optimization models. Validation is carried out on 1A1 grinding wheels via dressing and carbide grinding. The result is a practical design model for the targeted adjustment of porosity, bond strength, wetting, and self-sharpening, as well as guidelines for process windows that reduce non-productive times, increase process reliability, and shorten development cycles.

Benefits

Reduced dressing and non-productive times, higher process reliability and workpiece quality, longer service life, targeted self-sharpening, faster development cycles through knowledge-based design, energy and cost savings, robust recipes and standards despite raw material fluctuations.

Approach

The project follows a process chain-wide, experimental model-based approach. The first step involves characterizing the raw materials in terms of particle and powder properties, flow and bulk behavior, and reaction-specific effects after mixing and sintering. The second step involves the investigation of mixing, transport, and filling, including segregation analysis, mixing quality assessment, and filling density measurement. The third step involves precompaction and sintering, including process monitoring and subsequent microstructure and phase analysis (SEM/EDX, XRD) as well as mechanical tests, such as flexural strength. The fourth step involves the production of 1A1 grinding wheels, followed by grinding tests on carbide with force, wear, and roughness measurements to evaluate self-sharpening, process stability, and quality. The sixth and final step involves data-driven modeling in the form of effect diagrams, regression and optimization models for the design of bonds and process windows, as well as validation using prototype tools.

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Contact Thomas Geschwind  via email at geschwind@ifw.uni.hannover.de  or by phone at +49 511 762 18849.