Laser deflection tangential dressing complex-concave surface bronze-bonded diamond wheels

Laser dressing of super-hard abrasive concave surface diamond wheels is a very promising technology to overcome the shortcomings of current dressing methods. However, the technology is still at a preliminary stage of research, due to inadequate research on dressing methods and dressing principles, which makes it difficult to effectively shape. In this paper, a novel method named laser deflection tangential dressing was proposed for profiling concave complex-concave surface diamond wheels. The profile error after the tangential dressing was analyzed, and the compensation method was developed. The effects of the laser deflection angle and energy on the accuracy of dressing bevel edge profiles were investigated, and the impacts of the deflection angle and the compensation radius on dressing arc profiles were studied. The experimental results illustrated that the method of the laser deflection tangential dressing effectively solved errors in the dressing process. The PV value of the bevel edge profile dressing accuracy could reach about 8 μm at a deflection angle of 1–1.5°. With a suitable deflection angle, the radius deviation of the circular dressing profile could reach 10 μm with the compensation radius of 0.04 mm (for convex arc radius of 0.25 mm), 0.03 mm (for concave arc radius of 0.2 mm), and 0.06 mm (0.5 mm for concave arc), respectively. The overall profile error of the complex-concave surface was around 25 μm, and the surface morphology was relatively ideal. The grinding testing results of graphite and aluminum oxide workpieces were nearly the same, and the surface roughness Ra were 0.543 μm and 0.508 μm, respectively.