The dressing tool of the grinding wheel dressing machine is the core component to ensure the quality of grinding wheel dressing, and its wear rate directly affects the dressing accuracy and production cost. To solve the problem of rapid wear and tear, precise measures need to be taken from the aspects of tool characteristics, dressing parameters, and equipment status to extend the service life of the tool while ensuring the dressing effect.
The material and structural compatibility of the repair tool are the basis for reducing wear and tear. Diamond tools are the mainstream choice, but their performance differences are significant: single crystal diamond has high hardness but high brittleness, making it suitable for dressing low hardness grinding wheels; Polycrystalline diamond has better toughness and slower wear when dressing high hardness ceramic bond grinding wheels. If the tool material does not match the grinding wheel, such as using single crystal diamond to repair silicon carbide grinding wheel, the tool will quickly passivate due to the similar hardness of the abrasive particles. At this time, it should be replaced with a cubic boron nitride composite tool. The design of tool structure also needs to be optimized, using a large rake angle geometry can reduce cutting resistance and lower wear rate; Changing the tool fixing method from rigid clamping to elastic floating can cushion instantaneous impacts and avoid local collapse.
The reasonable setting of adjustment parameters is crucial for suppressing wear. Excessive dressing speed can exacerbate the accumulation of frictional heat between the tool and the grinding wheel, leading to thermal erosion and wear of diamond tools. It is necessary to reduce the linear velocity ratio according to the hardness of the grinding wheel, usually controlled within the range of 0.002-0.004. When the depth of a single trimming is too large, the cutting force borne by the tool increases sharply, which can easily cause blade breakage. The trimming strategy of "shallow cutting depth, multiple strokes" should be adopted, with the initial trimming depth not exceeding 0.02mm and gradually decreasing thereafter. Failure of the cooling system can cause tool overheating and wear. It is necessary to check the nozzle position to ensure that the coolant directly flushes the repair area. At the same time, extreme pressure emulsion should be used to enhance lubrication and reduce friction and wear.
Calibration of equipment status can reduce unnecessary wear and tear. Excessive radial runout of the spindle can cause uneven contact between the tool and the grinding wheel, leading to localized stress concentration and accelerated wear. It is necessary to control the runout within 0.01mm through dynamic balancing adjustment. The crawling phenomenon caused by insufficient feed accuracy of the guide rail can cause intermittent overload of the tool. Regularly cleaning the guide rail and adjusting the preload can restore smooth feed. In addition, the deviation of the verticality of the tool installation benchmark can lead to an imbalance in the distribution of cutting force. Calibrating the verticality of the tool axis and the grinding wheel end face with a square ruler can avoid local rapid wear caused by eccentric load.
In daily maintenance, it is necessary to establish a tool wear monitoring mechanism, observe the cutting edge status of the tool through a microscope, and promptly repair and grind any small broken edges; Idle tools should be stored properly in a dry environment to prevent diamond oxidation or moisture deterioration. Through comprehensive measures such as material adaptation, parameter optimization, equipment calibration, and maintenance strengthening, the problem of rapid wear of repair tools can be effectively solved, and production costs can be reduced while ensuring the quality of repair.