Electroplated grinding wheels, also known as electroplated grinding wheels or electroplated CBN/diamond grinding wheels, are grinding tools in which superhard abrasives (such as synthetic diamond or cubic boron nitride (CBN)) are firmly attached to the surface of a metal substrate (usually steel or aluminum alloy) through an electroplating process.
I. Core Structure and Manufacturing Principles
Base Body: Typically a metal wheel, the shape is determined by the application (e.g., flat, cup, or dish). It serves as the backbone of the grinding wheel, providing strength and a mounting base.
Abrasive Layer: Consists of a single or a few layers of superhard abrasive (diamond or CBN).
Bond: This is the key. A layer of metal (usually nickel or a nickel-cobalt alloy) is deposited onto the surface of the base through electroplating (electrodeposition). This metal layer simultaneously encapsulates the abrasive particles and "brazes" them to the base, forming a strong bond.
A simple analogy is like a magnet attracting a pile of iron sand, but the bonding force of electroplating is much stronger and more permanent. The electroplated layer acts like "superglue," adhering the hard "teeth" (abrasive) to the substrate.
II. Main Features
Due to its unique manufacturing process, electroplated grinding wheels offer the following significant advantages and limitations:
Advantages:
Extremely sharp and efficient grinding: High grit exposure, large chip volume, and smooth chip evacuation make them ideal for efficient, high-speed grinding.
High machining accuracy and excellent workpiece surface quality: Commonly used for fine grinding and superfinishing, they achieve very high dimensional accuracy and low surface roughness.
Simple manufacturing process and low cost: Compared to metal-bonded grinding wheels that require high-temperature sintering, the electroplating process operates at lower temperatures, has shorter cycle times, and is less expensive.
Excellent shape reproducibility: They can produce very complex and precise shapes (such as in form grinding and thread grinding) while maintaining high shape accuracy.
No Dressing Required: In most applications, electroplated grinding wheels require no dressing before use or throughout their lifespan, making them incredibly convenient and ready for immediate use.
Disadvantages/Limitations:
Relatively Low Wear Resistance: Because they are a single-layer abrasive, once the abrasive grains are completely worn away, the entire wheel becomes ineffective. While multi-layer electroplating is available, its durability is still inferior to that of sintered metal-bonded grinding wheels.
Bond Strength Limits: The bond strength of the electroplated layer is a combination of mechanical embedding and chemical bonding. Under extremely heavy grinding loads, there is a risk of premature abrasive grain removal.
Unable to Dress: This is a double-edged sword. While it eliminates the need for dressing, it also means that the geometry and grinding performance cannot be restored through dressing, making it a "disposable" tool.
III. Main Applications
Due to their high precision, high efficiency, and the absence of dressing requirements, electroplated grinding wheels are widely used in machining a variety of hard, brittle, and high-hardness materials:
Carbide Tools: Grinding and sharpening carbide turning tools, milling cutters, drill bits, etc.
Glass and Ceramic Machining: Edge grinding, engraving, and grooving.
Semiconductor Materials: Precision grinding and cutting of silicon wafers, sapphire, and magnetic materials.
Stone Machining: Engraving and polishing.
High-Hardness Alloy Steel: Grinding high-speed steel and mold steel using CBN electroplated grinding wheels.
Form Grinding: Precision machining of complex surfaces such as gears, threads, and splines.
