Abstract
In the present paper, a novel conditioning method for superabrasive grinding wheels based on surface structuring with ultrashort pulsed lasers is investigated. A picosecond laser (pulse duration tp = 10 ps) is utilised to ablate regular micro patterns into the surface of CBN grinding tools, aiming to reduce grinding forces and improve grinding efficiency. The proposed structuring method enables a high degree of control and flexibility regarding pattern geometry and feature size. An analysis of the ablated structures does not reveal any significant thermal deterioration of the abrasive grits resulting from the laser process. Grinding performance and wear behaviour of the structured tools are tested in a face grinding process of hardened steel type 100Cr6 (60HRC). The test results show that the structured tools enable between 25 to 50% lower forces and significantly improve force stability in long-term grinding operation, due to an enhanced self-sharpening effect of the tool. However, the best surface finish is still achieved with the non-structured tools. The experimental results further indicate that the pattern geometry has a much stronger influence on the grinding behaviour than the degree of structuring (meaning the percentage of active wheel surface compared to a non-structured tool).
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