A novel miniature diamond grinding tool usable for the precise micro-grinding of miniature parts is presented. A hybrid process that combines 'micro-EDM' with 'precision co-deposition' is proposed. The metal substrate is micro-EDMed to a 50 µm diameter and micro diamonds with 0-2 µm grains are 'electroformed' on the substrate surface, producing a miniature multilayered grinding tool. Nickel and diamond act as binders and cutters, respectively. A partition plate with an array of drilled holes is designed to ensure good convection in the electroforming solution. The dispersion of diamond grains and displacement of nickel ions are noticeably improved. A miniature funnel mould enables the diamond grains to converge towards the cathode to increase their deposition probability on the substrate, thereby improving their distribution on the substrate surface. A micro ZrO 2 ceramic ferrule is finely ground by the developed grinding tool and then yields a surface roughness of R a = 0.085 µm. The proposed approach is applied during the final machining process.
This study presents a novel, economical and efficient fabrication technique for precisely generating multiple microgrooves on a microscope slide to allow for microscopic examination of urine sediment cells. This study incorporates two important phases: a precision wheel-tool array is fabricated and then the developed tool is used in fast on-line grinding of multiple microgrooves. The wheel-tool blank is made of diamond grit of 0-2 μm grade via co-deposition. Subsequently, it is trued, sliced and sharpened by means of micro wire electro discharge dressing. The finished wheel-tool is utilized on-line to grind multiple microgrooves using 'high-speed and fast-shallow grinding'. A ductile grinding regime is established to obtain a nano-metric surface finish for the multiple microgrooves generated on the microscope slide. The depth and width of the grooves in the array are both 10 μm and a surface finish of R a equal to 0.010 μm is simultaneously achieved. This multiple microgrooving technique can supply high-quality fast grinding in the fabrication of bio-medical devices, such as those used for stationing and counting urine sediment cells.
This study presents a compound process combining composite electroforming with wire Electrical Discharge Machining (w-EDM) for developing a thin cubic boron nitride (CBN) grinding-tool. A precisely designed set-up in which a small compound depositing tank providing effectual convection of a compound electroplating solution to help fabricate a CBN grinding-blank is presented. A funneled entrance design for converging CBN grits in the working tank and creating a depositing effect on the substrate is employed and proposed. Considerable micro CBN abrasives are evenly embedded into the nickel-based coating layer, which offers enough abrasives for grinding-edge. Subsequently, the coated grinding-blank is trued and dressed by using w-EDM to form a multiple thin CBN grinding-tool. Experimental results indicate that the electroforming process can create a Ni-based CBN layer of high-integrity under current density of 2 ASD and concentration of 8.6 g/l CBN grits. Moreover, the CBN grinding-edge of 10 μm in thickness (each edge) can be achieved.
This study presents a novel and economical compound technique that combines co-deposition with micro w-EDM for precisely developing a multiple micro diamond wheel-tools. The wheel-blank is made of diamond grit of 0-2 µm grade by electrochemical technique, in which employs a designed micro tank with ideal convection and mini porous carrier. Using a pore size of 5-10-µm in the porous carrier, a suitable interval chip-pocket of 2-3 µm on wheel-blank can generate naturally. Formation of the multiple wheel-tools is carried out via the processes of slicing, thinning and dressing simultaneously to become grinding edges array. A circuit of resistance capacitance, which provides a very short pulse and high peak, is employed as the electrical discharge power to help in achieving a very shallow and narrow discharge cavity. The thickness of each grinding edge can be machined down to 10-µm. The experimental result shows that the proposed technique is an effective method to fabricate precision micro diamond wheel-tools.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.