Development of a thin CBN grinding-tool by compound process

This study presents a compound process combining composite electroforming with wire Electrical Discharge Machining (w-EDM) for developing a thin cubic boron nitride (CBN) grinding-tool. A precisely designed set-up in which a small compound depositing tank providing effectual convection of a compound electroplating solution to help fabricate a CBN grinding-blank is presented. A funneled entrance design for converging CBN grits in the working tank and creating a depositing effect on the substrate is employed and proposed. Considerable micro CBN abrasives are evenly embedded into the nickel-based coating layer, which offers enough abrasives for grinding-edge. Subsequently, the coated grinding-blank is trued and dressed by using w-EDM to form a multiple thin CBN grinding-tool. Experimental results indicate that the electroforming process can create a Ni-based CBN layer of high-integrity under current density of 2 ASD and concentration of 8.6 g/l CBN grits. Moreover, the CBN grinding-edge of 10 μm in thickness (each edge) can be achieved.