Wear evolution of metal bond diamond tool in grinding of sapphire

The wear characteristics of the metal bond diamond tools changes with the grinding process, resulting in affecting the grinding efficiency, tool's life, and surface integrity of the workpiece. In this study, the wear evolution of a metal bond diamond tool, for the case of grinding of sapphire, is investigated by using a novel design of the grinding setup. The wear characteristics of the diamond grits and the metal bond at a fixed zone of the grinding tool were examined. In addition, the evolution of the grinding process, the grinding force, the grinding ratio, and the surface integrity of the sapphire were also evaluated. As the material removal volume increases, the number of participating diamond grits, the proportion of micro-fractured diamond grits, and the average diamond grit protrusion height increase during the grinding process. And the proportion of newly exposed diamond grits decreases and the distribution of protrusion height of diamond grits becomes narrower during the grinding process. Consequently, a higher grinding ratio, stable grinding force, and excellent ground surface integrity are achieved positively when the wear of the metal bond diamond tool transforms from the initial stage to the stable stage with the material removal volume of up to 3600 mm3.