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Published in: The International Journal of Advanced Manufacturing Technology 7-8/2024

20-02-2024 | ORIGINAL ARTICLE

Grinding performances and failure analyses of electroplated Ni–B-diamond tools with a high density of single- or dual-layer D-150-diamond particles

Authors: Chia Hsuan Shen, Aphichart Rodchanarowan, Pin Yan Li, Chia Ching Huang, Yu Chieh Chen, Po Liang Lai, Ching An Huang

Published in: The International Journal of Advanced Manufacturing Technology | Issue 7-8/2024

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Abstract

This study explored the performance of electroplated grinding tools electroplated with single and dual-layer diamond particles (DPs). These tools were fabricated through a three-step electroplating process, involving Ni-undercoating, Ni-diamond co-electroplating, and Ni–B strengthen-electroplating, on AISI 440C steel rods. Grinding tool performance was assessed based on the maximum achievable ground length from slot-grinding Al2O3 plates. Dual-layer DP composite deposits with varying secondary Ni-undercoat thicknesses (0, 12, and 24 μm) all exhibited substantial improvements in tool’s grinding performance due to their self-sharpening effect. As the secondary Ni-undercoat thickness increased, the maximum ground length increased significantly, reaching values of 2234, 5366, and 9632 mm, respectively. Raman spectroscopy revealed the transformation of outer DPs into graphite structures during grinding tests, indicating the formation and subsequent delamination of these DPs, leading to morphological changes. Tool failure was attributed to the fatigue rupture of the AISI 440C tool shaft. During slot grinding, the tool shaft experienced cyclic stress due to a consistent grinding speed of 2 mm/min and spindle rotation of 15,000 rpm. High-cycle fatigue fracture, characterized by the absent of plastic deformation and a nearly perpendicular crack to the tool shaft, occurred after over 107 stress cycles.

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Literature
Metadata
Title
Grinding performances and failure analyses of electroplated Ni–B-diamond tools with a high density of single- or dual-layer D-150-diamond particles
Authors
Chia Hsuan Shen
Aphichart Rodchanarowan
Pin Yan Li
Chia Ching Huang
Yu Chieh Chen
Po Liang Lai
Ching An Huang
Publication date
20-02-2024
Publisher
Springer London
Published in
The International Journal of Advanced Manufacturing Technology / Issue 7-8/2024
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI
https://doi.org/10.1007/s00170-024-13205-7

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