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<p>In order to gain insight into the material removal mechanism of abrasive machining processes, single-grain cutting is a useful and widely adopted technique. In most of the works on this subject, the single abrasive grains are bonded to a substrate by soldering, electroplating or simple adhesive bonding. As a result, the grinding tool bond’s influence is largely neglected. This publication shows a new variant of single-grain cutting that makes it possible to quantify the influence of the bond on the material removal mechanism. Specimens with different bond hardness are prepared using a sintering-based additive printing process. In single-grain cutting experiments, the influence of the Rockwell hardness of different bond types on the material removal efficiency was investigated. Among other things, a reduction in the specific scratch energy by 40% and an increase in the grinding force ratio by 70% were found when using an iron-based bond with increased hardness, compared to a softer, steel-based bond. This is a result of an increased grain protrusion under load for the grains in the harder bonds which leads to an increased material removal efficiency.</p>

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Effect of Bond Hardness of Additively Manufactured Grinding Tool Bonds on Material Removal Efficiency during Single-Grain Cutting

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年1月30日

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  • Berend Denkena,
  • Thomas Weißgärber,
  • Thomas Studnitzky,
  • Benjamin Bergmann,
  • Alexander Strauß,
  • Lennart Puls

摘要

In order to gain insight into the material removal mechanism of abrasive machining processes, single-grain cutting is a useful and widely adopted technique. In most of the works on this subject, the single abrasive grains are bonded to a substrate by soldering, electroplating or simple adhesive bonding. As a result, the grinding tool bond’s influence is largely neglected. This publication shows a new variant of single-grain cutting that makes it possible to quantify the influence of the bond on the material removal mechanism. Specimens with different bond hardness are prepared using a sintering-based additive printing process. In single-grain cutting experiments, the influence of the Rockwell hardness of different bond types on the material removal efficiency was investigated. Among other things, a reduction in the specific scratch energy by 40% and an increase in the grinding force ratio by 70% were found when using an iron-based bond with increased hardness, compared to a softer, steel-based bond. This is a result of an increased grain protrusion under load for the grains in the harder bonds which leads to an increased material removal efficiency.