Due to the characteristics of the diamond roller shaping and dressing method, such as short dressing time, various kinds of complex surface dressing, good precision of surface dressing, convenient dressing operation, etc., its application effect has been gradually recognized by people, and has been more and more widely used in production.
However, the following points should be paid attention to in the design, manufacture and use of diamond rollers:
(1) the particle size of diamond should be one size coarsely than that of the dressing grinding wheel. In addition, the particle size of diamond should be nearly the same and the particle shape is nearly spherical. The commonly used particle size is 36 # ~100 #.
(2) the linear velocity direction at the contact point of the roller and the grinding wheel is usually in the same direction, and the ratio of the linear velocity of the roller and the grinding wheel (qd value) is better to be + 0.3 ~ + 0.7, which shall not exceed + 1; When dressing, the cutting amount of the grinding wheel should be 0.5 ~1 micron per revolution, and the total amount of each dressing grinding wheel should be 0.02 ~ 0.04mm. Minimize repair time.
(3) the manufacturing error of diamond roller should be less than 1/2 of the workpiece tolerance, and the matching clearance between roller hole and mounting bearing should be 2~4 microns.
(4) natural or artificial diamond can be used, and the artificial diamond must adopt high strength grade diamond, such as steel grinding special diamond SCD or high strength diamond SMD.
(5) when the roller is manufactured, the roller with general precision can be manufactured by external plating method and sintering method, and the roller with high precision and complex surface can be manufactured by internal plating method, and grinding and dressing can be carried out at the same time.
(6) when dressing the grinding wheel, the diamond roller must follow the operation procedure of fast forward (cannot touch the grinding wheel) → slow forward (feed at the required cutting speed) → light repair → exit, and shall not make any wrong step, otherwise, the service life of the roller cannot be guaranteed.