Research on the grinding performance of a defined grain arrangement diamond grinding wheel with small grit (95 μm)

A grain-arranged grinding wheel refers to a grinding wheel where the position of abrasive particles on the wheel can be customized. In this paper, the processing quality of the grain-arranged grinding wheel in different grain arrangements, including rectangle, rhomboid, and oblique rectangle arrangement, respectively, is compared with that of conventional grinding wheel in the grinding of single-crystal silicon. Comparisons have also been made between arranged wheel in oblique rectangle arrangement and conventional wheel in terms of 2D- and 3D-machined surface morphology, surface roughness, and grinding force. By considering the effects of the material removal process, abrasive grain interactions, and grain arrangement parameters, a grinding force model is built for the grain-arranged grinding wheel. Through processing experiments with different grinding wheels, it is found that the grain arrangement has a great influence on the machined surface quality. Rational and orderly grain arrangement can improve the machined surface quality and machining stability, but the machined surface quality of a grain-arranged wheel is not always better than that of a conventional wheel. Specifically, the machined surface quality of arranged wheels in rectangle arrangement is always the worst, but the difference of machined surface quality of the other three kinds of grinding wheels is not significant at low feeding velocity. With the increase of feeding velocity, the machined surface quality of arranged wheel in oblique rectangle and rhomboid grain arrangement will gradually be better than that of the conventional wheel. In respect of grinding force, it is found that arranged wheel in oblique rectangle arrangement owns a smaller average force and a more stable momentary force than that of the conventional grinding wheel. For the grinding force model built in this paper, its effectiveness and accuracy were finally verified by experiments.