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Application potential of coarse-grained diamond grinding wheels for precision grinding of optical materials

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Abstract

Fine-grained resin bonded diamond tools are often used for ultra-precision machining of brittle materials to achieve optical surfaces. A well-known drawback is the high tool wear. Therefore, grinding processes need to be developed exhibiting less wear and higher profitability. Consequently, the presented work focuses on conditioning a mono-layered, coarse-grained diamond grinding wheel with a spherical profile and an average grain size of 301 µm by combining a thermo-chemical and a mechanical-abrasive dressing technique. This processing leads to a run-out error of the grinding wheel in a low-micrometer range. Additionally, the thermo-chemical dressing leads to flattened grains, which supports the generation of hydrostatic pressure in the cutting zone and enables ductile-mode grinding of hard and brittle materials. After dressing, the application characteristics of coarse-grained diamond grinding wheels were examined by grinding optical glasses, fused silica and glass–ceramics in two different kinematics, plunge-cut surface grinding and cross grinding. For plunge-cut surface grinding, a critical depth of cut and surface roughness were determined and for cross-grinding experiments the subsurface damage was analyzed additionally. Finally, the identified parameters for ductile-machining with coarse-grained diamond grinding wheels were used for grinding a surface of 2000 mm2 in glass–ceramics.

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Acknowledgments

The authors would like to thank the German Research Foundation (Deutsche Forschungsgemeinschaft DFG) for funding the project “Engineered Grinding Wheels”—Deterministisches Präzisionsschleifen optischer Gläser (#BR 825/53-3).

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Authors and Affiliations

  1. Laboratory for Precision Machining (LFM), University of Bremen, Badgasteiner Str. 2, 28359, Bremen, Germany

    Ekkard Brinksmeier, Oltmann Riemer, Kai Rickens & Daniel Berger

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  1. Ekkard Brinksmeier
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  2. Oltmann Riemer
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  3. Kai Rickens
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  4. Daniel Berger
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Correspondence to Daniel Berger.

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Brinksmeier, E., Riemer, O., Rickens, K. et al. Application potential of coarse-grained diamond grinding wheels for precision grinding of optical materials. Prod. Eng. Res. Devel. 10, 563–573 (2016). https://doi.org/10.1007/s11740-016-0699-y

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  • DOI: https://doi.org/10.1007/s11740-016-0699-y

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