Dual-laser dressing concave rectangular bronze-bonded diamond grinding wheels

Abstract

Laser ablation is an effective and advantageous dressing method for dressing diamond grinding wheels. Previously, research on laser dressing has focused on parallel and convex face diamond wheels. Studies of the laser dressing model analysis and the sources of shape error for concave diamond wheels are less numerous. There is no research to analyse the source of the diamond wheel error from the optics itself. In this paper, a novel deflectable dual-laser misaligned tangential (DDLMT) dressing method was proposed for processing concave rectangular bronze-bonded diamond wheels. Using the DDLMT process, the slope effect error in dressing concave rectangular diamond wheels was basically eliminated. To analyse the causes of the slope effect error during profiling, a theoretical study of the laser radial and tangential dressing methods was carried out, and a mathematical model was established to analyse the laser energy loss mechanism. Experiments on different positions dressings were conducted to validate the mathematical model. The DDLMT dressing method offered a significant improvement in contour accuracy and more than doubled the dressing efficiency compared to single beam profiling. As the laser deflection angle increased, the angle deviation of the dressed right-angle contour gradually decreased. The least deviation of right-angle profile obtained was 0.51° when the deflection angle was 5°. The final PV value of the bottom contour was 11.83 μm, which had a better contour accuracy. The surface quality of the grinding wheel by DDLMT dressing is far better than that of radial dressing. The experimental results demonstrated the potential of the DDLMT dressing method for precision profiling diamond wheels.