Abstract
An approach for fabricating a diamond conditioner by using a micro patterning and nickel electroforming method is demonstrated to improve the material removal rate (MRR) and the diamond worn ratio. By compared with the currently commercial conditioner, our developed diamond conditioner performs approximate 35% of the MRR and 18% of diamond worn ratio. The contact surface between the diamond and the counterpart is increased by the well-controlled of the grit protrusion which is within the range of 1.36 micrometer. This protrusion control not only results in the MRR and frictional coefficient increase, but also the load force reduction on each diamond grit during a wearing test. Furthermore, a chemical treatment is utilized to functionalize the surface of the diamond grits for the adhesion enhancement which can eliminate the matrix defects at the interface between the grits and nickel matrix.
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