216 Ultra High Speed and High Efficiency Grinding for Mirror-Like Surface Finish

Wakuda, Manabu; Nakayama, T.; Takashima, K.; Ota, Masahiro

doi:10.1299/jsmelem.2003.285

Cited by 9 publications

(13 citation statements)

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“…Based on this idea, several researchers have tried to condition the electroplated mono-layer diamond wheels with coarse grain sizes for realizing ductile grinding of brittle materials [7][8][9][10][11][12][13]. Ekkard Brinksmeier et al [7] concluded that the essential requirement for a successful application of such a kind grinding wheel in ductile grinding of optical glasses is the generation of a special grinding wheel topography consisting of flattened grain tops with a very constant peripheral envelope resulting in a minimized radial run-out of the grinding wheel.…”

Section: Introductionmentioning

confidence: 99%

“…Surely, this kind of wheel would be a perfect choice but, at times being would be difficult to manufacture. Wakuda et al [9] have proposed a truncating method for dressing a coarse-grained CBN wheel for grinding hardened steel and obtained a mirror-like finish with Ra 0.05 m. Hwang et al [11][12][13] have used electroplated diamond wheels for high speed grinding of silicon nitride and investigated the wheel wear, wheel life, wheel topography. However, there have been no reports so far of the successful application of coarse-grained diamond wheels for ductile contour grinding of optical glasses.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Ultra-precision grinding of optical glasses using mono-layer nickel electroplated coarse-grained diamond wheels. Part 1: ELID assisted precision conditioning of grinding wheels

Zhao

Guo

2015

Precision Engineering

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Ultra-precision grinding of optical glasses using mono-layer nickel electroplated coarse-grained diamond wheels. Part 1: ELID assisted precision conditioning of grinding wheels

Zhao

Guo

2015

Precision Engineering

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“…Several researchers have tried to apply this new diamond wheel in ductile grinding of brittle materials [1,2,3,4,5,6,7]. Ekkard Brinksmeier et al [1] have proposed conditioning technique that features the useof a diamond cup wheel to dress the coarse-grained diamond wheel and a radial run-out error of less than 2µm was achieved, and ductile mode taper grinding was realized on optical glasses.…”

Section: Introductionmentioning

confidence: 99%

“…Surely this kind wheel is a perfect choice but at moment it is very difficult manufacture. M. Wakuda et al [3] proposed a truncating method to dress a coarse-grained CBN wheel in grinding hardened steel and a mirror-like surface with Ra 0.05µm was obtained. T. W. Hwang [5,6,7] et al used unconditioned electroplated diamond wheels on high speed grinding of silicon nitride, by which the wheel wear, wheel life, wheel topography and grinding mechanism were investigated.…”

Section: Introductionmentioning

confidence: 99%

ELID Assisted Precision Conditioning of Coarse-Grained Diamond Grinding Wheel

Zhao

Brinksmeier

Riemer

et al. 2007

KEM

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In order to realize ductile machining of optical glasses using mono-layer nickel electroplated coarse-grained diamond grinding wheel, a novel conditioning technique features using a copper bonded diamond grinding wheels of 15m grain size dressed by ELID (electrolytic inprocess dressing) to condition the 46m grain sized diamond wheel has been developed. During the conditioning process, a force transducer was used to monitor the conditioning force, a coaxial optical distance measurement system was used to in-situ monitor the modified wheel surface status. White-light interferometry (WLI), scanning electron microscopy (SEM) and atomic force microscopy (AFM) were used to characterize the conditioned wheel surface status as well as the ground optical glass surface topography correspondingly. The experimental result indicates that a minimized wheel radial run-out error of less than 2μm as well as the top-flattened diamond grains of constant wheel peripheral envelop profile were generated on a 5-axis ultra-precision machine tool. The grinding experiment proved that the well conditioned 46μm coarse-grained diamond wheel can be used in realizing the ductile grinding of optical glass BK7, which indicates that the newly developed conditioning technique is feasible and applicable to introduce the coarse-grained diamond wheels into precision machining of brittle and hard-to-machine materials.

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“…This kind of wheel had perfect grinding performance, but was not easy to manufacture. The unsolved problem for manufacturing electroplated nickel diamond wheels is the uncontrollability of diamond grain concentration and grain protrusion height beyond the bonding material surface [8]; Wakuda et al [3] proposed a truncating method to dress a coarse-grained CBN wheel in grinding hardened steel, and a mirror-like surface with Ra 0.05 µm was obtained. Hwang et al [5−7] used unconditioned electroplated diamond wheels on high speed grinding of silicon nitride to investigate wheel wear, wheel life, wheel topography and grinding mechanism.…”

mentioning

confidence: 99%

Ultra-precision ductile grinding of BK7 using super abrasive diamond wheel

Brinksmeier

Zhao

Riemer

et al. 2007

Front. Mech. Eng. China

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fine-grained resin or metal bonded diamond wheels. However, a disadvantage of this technology is the large wear rate of the grinding wheel during the dressing and grinding process, which limits the achievable figure accuracy and the maximum material removal volume, especially in the case of ductile grinding large spherical and aspherical optical surfaces. To solve this problem, a new diamond wheel type with grinding ratio significantly larger than that of finegrained diamond wheels must be applied to guarantee surface form accuracy of the machined surface.Monolayer nickel electroplated coarse-grained diamond grinding wheels have a grain size of approx of 100 µm. Because they can satisfy the requirements mentioned above, they could theoretically be a promising solution to the problem of using fine-grained diamond wheels to obtain topflattened diamond grains with minimized wheel run-out error, provided that they are well conditioned before machining.Based on this idea, several researchers have tried to apply this new diamond wheel in ductile grinding of brittle materials [1−7]. Brinksmeier et al. [1] proposed that a diamond cup wheel be used to dress the coarse-grained diamond wheel: a radial run-out error of less than 2 µm was obtained, and ductile mode taper grinding was realized on the optical glasses. However, no further contour grinding trials had been conducted; Kanai et al. [2] proposed the construction of a new diamond wheel, where the abrasives are monocrystalline pillar diamond and the orientations are aligned. This kind of wheel had perfect grinding performance, but was not easy to manufacture. The unsolved problem for manufacturing electroplated nickel diamond wheels is the uncontrollability of diamond grain concentration and grain protrusion height beyond the bonding material surface [8]; Wakuda et al. [3] proposed a truncating method to dress a coarse-grained CBN wheel in grinding hardened steel, and a mirror-like surface with Ra 0.05 µm was obtained. Hwang et al. [5−7] used unconditioned electroplated diamond wheels on high speed grinding of silicon nitride to investigate wheel wear, wheel life, wheel topography and grinding mechanism. However, there have been no reports so far of the successful application of coarse-grained diamond wheels on ductile contour grinding of optical glasses.Abstract In this paper, a novel conditioning technique using copper bonded diamond grinding wheels of 91 µm grain size and electrolytic in-process dressing (ELID) is first developed to precisely and effectively condition a nickelelectroplated monolayer coarse-grained diamond grinding wheel of 151 µm grain size. Under optimised conditioning parameters, the super abrasive diamond wheel was well conditioned in terms of a minimized run-out error and flattened diamond grain surfaces of constant peripheral envelope. The conditioning force was monitored by a force transducer, while the modified wheel surface status was in-situ monitored by a coaxial optical distance measurement system. Finally, the grinding experiment on BK7...

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216 Ultra High Speed and High Efficiency Grinding for Mirror-Like Surface Finish

Cited by 9 publications

References 0 publications

Ultra-precision grinding of optical glasses using mono-layer nickel electroplated coarse-grained diamond wheels. Part 1: ELID assisted precision conditioning of grinding wheels

Ultra-precision grinding of optical glasses using mono-layer nickel electroplated coarse-grained diamond wheels. Part 1: ELID assisted precision conditioning of grinding wheels

ELID Assisted Precision Conditioning of Coarse-Grained Diamond Grinding Wheel

Ultra-precision ductile grinding of BK7 using super abrasive diamond wheel

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