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PCD micro-grinding tools are extensively used in the finishing of brittle materials with wide applications in areas requiring very high surface finish. These micro-tools have several variations in terms of the size of the diamond grits used in the cobalt binder. In the present study, two variations of micro-EDM, namely WEDG, and block-EDG, were employed to dress cylindrical and tapered tools with grit sizes of 5 μm and 10 μm, respectively. Block-EDG proved to be the superior choice for efficient bulk material removal and significant diametral reduction. In contrast, WEDG exhibited a relatively lower material removal rate but was well-suited for precise finish dressing and truing. Finally, a hybrid approach was adopted for the final production of both types of tools, resulting in dimensionally accurate forms with the required surface quality.

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The Effect of Dressing Methods on the Form Accuracy of Sintered PCD Micro-Grinding Tools

  • 会议论文

  • 发表日期：

    2026年

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  • Anang Katyayan,
  • Probir Saha,
  • Afzaal Ahmed

摘要

PCD micro-grinding tools are extensively used in the finishing of brittle materials with wide applications in areas requiring very high surface finish. These micro-tools have several variations in terms of the size of the diamond grits used in the cobalt binder. In the present study, two variations of micro-EDM, namely WEDG, and block-EDG, were employed to dress cylindrical and tapered tools with grit sizes of 5 μm and 10 μm, respectively. Block-EDG proved to be the superior choice for efficient bulk material removal and significant diametral reduction. In contrast, WEDG exhibited a relatively lower material removal rate but was well-suited for precise finish dressing and truing. Finally, a hybrid approach was adopted for the final production of both types of tools, resulting in dimensionally accurate forms with the required surface quality.