Non-linear diamond material removal at increased sliding velocities in ultra-precision grinding

Abstract

Single crystal diamond machining primarily relies on mechanical grinding, traditionally guided by the simplistic concept of a linear removal rate. However, this conventional approach lacks precision in predicting the resultant shape. This comprehensive study delves into the influence of sliding speed on the material removal rate during the mechanical grinding of diamond, leveraging both theoretical frameworks and experimental exploration. Initially, the impact of sliding velocity is meticulously scrutinized by considering the contact frequency between the diamond and grinding wheel grits, as well as the depth associated with the brittle-ductile transition of diamond material. Subsequently, a model quantifying the effect of sliding velocity is meticulously formulated and rigorously tested through experimentation. The findings of this investigation not only affirm the validity of the theoretical analyses but also underscore the remarkable predictive accuracy of the sliding velocity effect model. These results, situated at the intersection of theory and practice, offer invaluable insights with profound implications for enhancing the efficiency and precision of single crystal diamond machining processes.