Diamond Tool Wear - Observation by SEM.pdf

Shai N. Shafrir ????? ?? Abstract In Deterministic Microgrinding (DMG), the wear of diamond grains is a significant problem and the cause for lowering grinding efficiency, which leads to “pull-out” (loose) of diamond grains from the binder and the appearance of scratching. It contributes to poor surface finish, increased machining forces, and increased tooling costs. At the Center for Optics Manufacturing (COM), we have been primarily interested in resin and bronze bonds diamond tools with a diamond size of ~2-4 microns. Unfortunately it is difficult to directly measure fine abrasives mechanical response. A qualitative model was introduced using Scanning Electron Microscopy (SEM) to better analyze diamond wear for different bond matrixes. Observation of the tool face after a variety of grinding and dressing operations provided characteristically different surfaces for each case. Fig 1. Bronze tool after 8 working cycles (BSE detector) After Dressing 3 cycles 6 cycles 8 cycles Pseudo Colors Summary and Conclusions Images were taken on the LEO 982 FE-Scanning Electron Microscope (SEM) at the University of Rochester Calibration info: Actual magnification is twice what is recorded on the images. Scale bar is in true value. Introduction Tools are constructed of a wearable matrix embedded with diamond particles and can vary in diamond size, abrasive concentration, and bond material. Ultimately the matrix ability to wear can have a large impact on the tool ability to grind the material, resulting in tool failure when it is not wearing properly. Excelerated tool wear will result in a dull tool surface, and will subsecwently loss its ability to remove work material. A better understanding of tool wear mechanism is needed in order to find an optimum condition between these two extremes, by maintaining proper grinding conditions to eliminate tool failure. The tool wear process is often broken into three modes of removal: 1) Diamond blunting, 2) Diamond pullout, and 3) Bond