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Investigation Of Diamond Cutting Tool Lapping System Based On On-Machine Image Measurement
2021-06-30

The profile tolerance of the diamond cutting tool’s edge is one of the key factors in affecting machining accuracy. With the development of ultra-precision machining technology for optical free-form surfaces and optical microstructures, the demand for high-precision round nose diamond cutting tools is increasing.

In this study, an on-machine image processing approach is applied to the cutting edge geometry truing process, and profile data of cutting edge in sub-pixel precision is acquired using a series of image processing methods. According to the profile captured, the deviation from an ideal cutting edge is calculated and feedbacked to the controller.

The lapping system is employed to lap the cutting edge pertinently using the deviation and the corresponding position captured, and the round edge of high accuracy is obtained efficiently.

This method can avoid the error caused by the process of fixturing for offline measurement in the traditional lapping method of diamond cutting tool and reduce the influence of human factors.

A truing experiment for cutting edge of the monocrystal diamond cutting tool is carried out at the developed lapping system based on on-machine image measurement, and the round cutting edge of profile tolerance is less than or equal to ±0.5 μm is achieved.

diamond cutting tool

The bonding between steel and diamond is carried out by induction brazing under a vacuum atmosphere. The filled intermediate layer material is a reactive Ni Cr alloy slice.

The results show that a chromium carbide film is formed on the interface between the diamond and the filled intermediate layer, also(Fe xCr y)C between the steel surface and the filled intermediate layer. Finally, a grinding test shows that the wear modes of such a brazed grinding wheel are mainly grit fracture and attrition rather than grit dislodgement from the bond.