The dressing methods for resin-bonded diamond grinding wheels mainly include mechanical dressing, electric spark dressing, laser dressing, chemical dressing, etc. The following is a detailed introduction:
Mechanical dressing method
• Single-point diamond dressing: Use a single-point dressing tool such as a diamond pen to remove the abrasive grains and binder on the surface of the grinding wheel through contact and friction with the surface of the grinding wheel to restore the shape and sharpness of the grinding wheel. During dressing, the diamond pen moves on the surface of the grinding wheel at a certain feed speed and pressure to scrape off the protruding abrasive grains and blocked binder. This method is suitable for situations where the dressing accuracy requirements are high and the grinding wheel wear is not too serious. It can obtain better surface quality, but the dressing efficiency is relatively low.
• Roller dressing: Use a roller with a certain shape and size to squeeze and rub against the surface of the grinding wheel to dress the grinding wheel. The roller can be a diamond roller or a silicon carbide roller. The roller dressing method is highly efficient and can effectively dress the grinding wheel profiles of various shapes. It is often used in mass production and occasions with high dressing efficiency requirements, but the manufacturing and installation costs of rollers are relatively high.
• Milling dressing: The grinding wheel is milled with a milling cutter to remove the excess part of the grinding wheel surface. Milling dressing can quickly remove a large amount of grinding wheel material and is suitable for situations where the grinding wheel is severely worn and requires a large amount of dressing. However, due to the large cutting force during the milling process, it may have a certain impact on the accuracy and surface quality of the grinding wheel, and further fine dressing is required after dressing.
Electric spark dressing method
• Principle: Based on the principle of electric spark discharge corrosion, a pulse voltage is applied between the tool electrode and the grinding wheel, so that the working fluid between the electrode and the grinding wheel surface generates spark discharge, and instantly generates high temperature, so that the metal binder and abrasive on the surface of the grinding wheel are melted and vaporized, thereby achieving the dressing of the grinding wheel.
• Features: The EDM dressing method has high dressing accuracy for grinding wheels, and is especially suitable for dressing high-hardness and high-brittle resin-bonded diamond grinding wheels. It can effectively remove blockages on the surface of the grinding wheel and restore the cutting performance of the grinding wheel. Moreover, during the dressing process, the tool electrode does not directly contact the grinding wheel, there is no mechanical force, and it will not cause deformation and damage to the grinding wheel. However, the cost of EDM dressing equipment is relatively high, and the electrical parameters need to be controlled during the dressing process, otherwise the dressing effect may be affected.
Laser dressing method
• Principle: Use a high-energy-density laser beam to irradiate the surface of the grinding wheel, so that the resin bond and abrasive particles on the surface of the grinding wheel are quickly melted, vaporized or decomposed at high temperature, thereby achieving the purpose of dressing the grinding wheel.
• Features: Laser dressing has the advantages of non-contact, high precision, and high flexibility. It can accurately dress grinding wheels of complex shapes, and can perform micro-structure processing on the surface of the grinding wheel as needed to improve the cutting performance of the grinding wheel. Laser dressing can also selectively remove abrasive grains and binders on the surface of the grinding wheel without damaging the grinding wheel matrix, which is suitable for occasions with extremely high requirements for dressing accuracy and surface quality. However, laser dressing equipment is expensive, has high operating costs, and has high technical requirements for operators.
Chemical dressing method
• Chemical corrosion dressing: Use chemical solutions to corrode and dissolve the resin binder on the surface of the grinding wheel, so that the grinding chips and binders blocked on the surface of the grinding wheel are removed, thereby restoring the porosity and cutting performance of the grinding wheel. Commonly used chemical solutions include corrosive liquids such as acids and alkalis. This method is relatively simple to operate and has low costs, but the dressing process is difficult to accurately control, which can easily cause excessive corrosion on the surface of the grinding wheel, affecting the dimensional accuracy and service life of the grinding wheel.
• Electrolytic dressing: The grinding wheel is used as an anode and placed in an electrolyte. The metal binder on the surface of the grinding wheel is dissolved by electrolysis, thereby achieving the dressing of the grinding wheel. The electrolytic dressing method can effectively remove the binder on the surface of the grinding wheel, make the abrasive grains protrude, and improve the sharpness of the grinding wheel. At the same time, the gas generated during the electrolytic dressing process can also play a certain flushing role, helping to remove impurities on the surface of the grinding wheel. However, electrolytic dressing requires special electrolytic equipment, and the treatment and recovery of the electrolyte need to pay attention to environmental protection issues.
Ultrasonic vibration dressing method
• Principle: Introduce ultrasonic vibration into the grinding wheel dressing process, convert electrical energy into mechanical energy through the ultrasonic transducer, so that the dressing tool or grinding wheel produces high-frequency vibration. Under the action of vibration, the contact state between the dressing tool and the grinding wheel surface changes, which enhances the removal effect of the dressing tool on the grinding wheel surface and improves the dressing efficiency and quality.
• Features: Ultrasonic vibration dressing can reduce the dressing force, reduce the damage and cracks on the grinding wheel surface, and is especially suitable for the dressing of resin-bonded diamond grinding wheels made of brittle materials. At the same time, the vibration effect of ultrasound can also improve the microstructure of the grinding wheel surface and improve the cutting performance of the grinding wheel. However, ultrasonic vibration dressing equipment is relatively complex, and it is necessary to reasonably select and adjust the vibration parameters to achieve the best dressing effect.
