Study On Design Method Of Electroplated Diamond Wheels With Remanufacturing Characteristics

Expensive diamond abrasives usually remained within scrap diamond tools. Recoveryand reuse of residual diamond grits, bond material and tool substrate can reduce resourcewaste and is accord with the sustainable development strategy. Based on interface failure ofbonding materials, a dismountable green design method was applied to the structure design ofelectroplated diamond wheel. The interface failure between abrasive layer and wheel substrateduring the separation process was discussed, which can contribute to a green and efficientseparation of abrasive layer from grinding wheel parts. Therefore, the recycling processes ofgrinding wheel, which are using-scrap-recovery-remanufacturing, can be realized.Three new dismountable structures of electroplated diamond wheels, which were calledpins-style, slider-style and assistant substrate-style, were proposed. Recycling andremanufacturing technology flow charts for electroplated diamond wheels were established.Interface failure modes, stress state and cracking location for electroplated layer separatingprocesses were analyzed with analytical and FEM methods, respectively. The local wheelstructures were modified to improve abrasive layer surface quality, wheel reuse ratio andreliability. The fabrication, recovery and remanufacturing for electroplated diamond wheelswere carried out. Research results show that the three type dismountable electroplateddiamond wheels can realize the separation of abrasive layer and substrate during thedisassembling process. The initial cracking points of abrasive layer in the surface of pins-stylewheel occurred at the endpoints of through-hole diameter along abrasive layer circumferentialdirection. The assembly clearance less than0.04mm can get a smoother abrasive layer. Theinitial cracking points of slider-style wheel occurred at the intersections between pin end-faceand substrate end-face. A symmetrical semicircular slide can improve the surface quality ofabrasive layer and the utilization times of electroplated diamond wheel. The initial crackingpoint of assistant substrate-style wheel occurred at the center line of abrasive cracking layer.The substrate with oblique slot can improve interface failure degrees. The slider that outercircular arc is longer than inner circular arc, and that is featured with non-equal out circulararc, can improve the working security of wheel.The experimental results proved the feasibility of wheel structure design. Thedisassembling process is simple and environmentally friendly. The designed electroplateddiamond wheels can realize the green separation of abrasive layer and substrate, and theremanufacturing of diamond wheels.