applied
sciences
Article
Research and Progress on Truing and Sharpening Process of
Diamond Abrasive Grinding Tools
Song Cai 1,2,3 , Wenhao Liu 1 , Jinchao Song 1 , Kai Deng 1 and Yinghong Tang 1, *
Citation: Cai, S.; Liu, W.; Song, J.;
Deng, K.; Tang, Y. Research and
Progress on Truing and Sharpening
Process of Diamond Abrasive
Grinding Tools. Appl. Sci. 2022, 12,
4683. https://doi.org/10.3390/
app12094683
Academic Editors: Jingwei Zhao,
Zhengyi Jiang, Leszek
Adam Dobrzański and Chong
Soo Lee
Received: 5 April 2022
Accepted: 27 April 2022
Published: 6 May 2022
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with regard to jurisdictional claims in
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iations.
Copyright: © 2022 by the authors.
Licensee MDPI, Basel, Switzerland.
This article is an open access article
distributed under the terms and
conditions of the Creative Commons
Attribution (CC BY) license (https://
creativecommons.org/licenses/by/
4.0/).
Appl. Sci. 2022, 12, 4683. https://doi.org/10.3390/app12094683
1 School of Mechanical Engineering, Hunan University of Technology, Zhuzhou 412007, China;
happy9918@sina.com (S.C.); lwh9706@126.com (W.L.); 17720163097@163.com (J.S.); dk123dk@163.com (K.D.)
2 School of Mechanical Science & Engineering, Huazhong University of Science and Technology,
Wuhan 430074, China
3 Green Fan Manufacturing Collaborative Innovation Center in Hubei Province,
Wuchang Institute of Technology, Wuhan 430065, China
* Correspondence: aaa492938174@sina.com
Abstract: With respect to the truing and sharpening of diamond abrasive grinding tools, traditional
machining methods are briefly described, and new dressing methods, such as the laser dressing
method, are described in detail. It is pointed out that laser dressing of diamond abrasive tools is a
green processing method with high efficiency and no environmental pollution. Numerical simulation
research on pulse laser dressing of a bronze diamond abrasive grinding wheel was carried out, and a
cumulative heat transfer model of laser dressing energy was developed. The temperature evolution
law of the bronze bond and diamond abrasive grains dressed by pulsed fiber laser was determined
by numerical analysis of the model. An experiment on the laser dressing grinding wheel was carried
out; it was found that when the laser power density was 2.52 × 108 W/cm2 ∼3.36 × 108 W/cm2 , the
bronze bond materials could be properly removed, and the diamond abrasive grains could be better
sharpened. The laser dressing method can achieve the combination of diamond abrasive grinding
tool sharpening and truing. The experiment not only demonstrated the correctness and feasibility of
the theoretical model but also provided process optimization for research into pulse laser dressing of
diamond abrasive grinding tools.
Keywords: diamond abrasive grinding tools; truing and sharpening; data analysis; dressing technology
1. Introduction
With the continuous development of science and technology, super-hard abrasive
grinding tools have gradually replaced ordinary abrasive grinding tools and become
the main means of high-quality, efficient, and precise machining of difficult-to-machine
materials. Super-hard abrasive grinding wheels often employ synthetic diamond and cubic
boron nitride (CBN) as abrasives and use ceramics, metals, and resins as the bonds, which
have high processing durability and can improve the surface quality of workpieces, making
them more suitable for automated production. Super-hard abrasive grinding wheels are
the basis for high-speed and ultra-high-speed grinding, and high-efficiency, ultra-precision
grinding [1].
Diamond abrasive grinding tools are the most widely used super-hard abrasive grind-
ing tools. During the grinding process, the abrasive grains will be gradually rounded
and blunted under the action of friction and extrusion force. During grinding, the grains
will slip with the workpiece and may cause vibration and noise, which will affect the
shape accuracy and roughness of the workpiece surface and reduce grinding efficiency
and grinding performance. The dressing technology of diamond abrasive grinding tools,
which is often restricted by a series of factors, such as dressing efficiency, dressing accuracy,
dressing tools, and complex surface dressing, is presently an urgent problem to be solved.
https://www.mdpi.com/journal/applsci
 2. Dressing Status of Diamond Abrasive Grinding Tools
The development of grinding technology has experienced three stages: o
grinding, precision grinding, and ultra-precision grinding [2]. With the develop
Appl. Sci. 2022, 12, 4683 2 of 21
various new materials, the ordinary grinding wheel cannot meet their increas
cessing requirements. The role of the diamond abrasive grinding wheel is promin
2.its application
Dressing Statusisofincreasing
Diamond Abrasiverapidly.Grinding
In addition,
Tools the shaping accuracy and topogra
important indicators for the quality evaluation
The development of grinding technology has experienced of diamond abrasive
three stages: grinding t
ordinary
cause the
grinding, shaping
precision accuracy
grinding, determines the
and ultra-precision dimensional
grinding accuracy
[2]. With the and surface
development of q
the grinding
various workpiece,
new materials, the ordinaryandgrinding
the topography
wheel cannotdetermines the holding
meet their increasing processing force of
grains and the chip holding space around them.
requirements. The role of the diamond abrasive grinding wheel is prominent and its
application is increasing rapidly. In addition, the shaping accuracy and topography are
The dressing of diamond abrasive tools mainly includes two steps: truing an
important indicators for the quality evaluation of diamond abrasive grinding tools, because
ening.
the shapingTruing refers
accuracy to cutting
determines the blunt diamond
dimensional abrasive
accuracy grains
and surface to make
quality of thetheir tip
broken workpiece,
grinding and obtain andappropriate
the topographyshape accuracy
determines the to formforce
holding a sharp grinding
of abrasive grainsedge. Sha
refers
and to removing
the chip holding spacethearound
excessthem.
bond materials between diamond abrasive grains,
The dressing of diamond abrasive tools mainly includes two steps: truing and sharp-
them possess appropriate chip holding space, and making the grinding edge hig
ening. Truing refers to cutting blunt diamond abrasive grains to make their tips finely
the bond
broken and to obtain
obtain the ideal
appropriate abrasive
shape accuracy grain height
to form a sharpand form the
grinding cutting
edge. Sharpeningedge [3]. Th
ing technology
refers to removing the of diamond
excess bondabrasive
materials grinding tools has
between diamond developed
abrasive step-by-step f
grains, making
traditional single “hard touch” dressing [4], and a series of effectivethan
them possess appropriate chip holding space, and making the grinding edge higher dressing m
have been obtained, as shown in Figure 1. It can be seen from Figure 1 that impro
the bond to obtain the ideal abrasive grain height and form the cutting edge [3]. The
dressing technology of diamond abrasive grinding tools has developed step-by-step from
in traditional machining technologies, such as the diamond pen truing method, g
the traditional single “hard touch” dressing [4], and a series of effective dressing methods
method,
have rolling as
been obtained, method,
shown infree abrasive
Figure grain
1. It can be seensharpening
from Figure 1 method, consolidated
that improvements
tool
in sharpening
traditional method,
machining and the
technologies, innovation
such of new
as the diamond penprocessing
truing method, technologies,
grinding suc
electric discharge machining (EDM) dressing method and laser dressing method,
method, rolling method, free abrasive grain sharpening method, consolidated dressing tool
sharpening method, and the innovation of new processing technologies, such as the electric
vide feasible schemes for the development of diamond abrasive grinding tools
discharge machining (EDM) dressing method and laser dressing method, can provide feasi-
technology.
ble schemes for the development of diamond abrasive grinding tools dressing technology.

Figure
Figure 1. 1. Diamond
Diamond abrasive
abrasive grinding
grinding tools technology.
tools dressing dressing technology.
 3. Dressing Method of Diamond Abrasive Grinding Tools
Appl. 3.1. Truing
Sci. 2022, 12, 4683Technology of Diamond Abrasive Grinding Tools 3 of 21

Truing technology of diamond abrasive grinding tools refers to the process of micro-
dressing diamond abrasive grains to make their tips finely broken and obtain appropriate
3. Dressing Method of Diamond Abrasive Grinding Tools
shape accuracy to obtain the grinding
3.1. Truing edge.
Technology of At Abrasive
Diamond present, the truing
Grinding Tools technology of diamond
abrasive grinding tools mainly includesofthe
Truing technology diamond
diamond pengrinding
abrasive truingtools
method, rolling
refers to method,
the process of micro-
grinding method, EDM truing
dressing method,
diamond and
abrasive the to
grains laser
maketruing method.
their tips finely broken and obtain appropriate
shape accuracy to obtain the grinding edge. At present, the truing technology of diamond
abrasive grinding tools mainly includes the diamond pen truing method, rolling method,
3.1.1. Diamond Pen Truing Method
grinding method, EDM truing method, and the laser truing method.
The diamond pen truing method is a traditional mechanical truing method; a sche-
3.1.1. Diamond Pen Truing Method
matic diagram is shown in Figure 2. The diamond abrasive grinding wheel rotates clock-
The diamond pen truing method is a traditional mechanical truing method; a schematic
wise. The diamond diagram
pen is installed
is shown inon the2.fixed
Figure frame and
The diamond forms
abrasive a 90°
grinding angle
wheel with
rotates the
clockwise.
diamond abrasive grinding
The diamondwheel.
pen isThe tip of
installed onthe diamond
the fixed penforms
frame and aimsa 90
at the
◦ anglehigh
with point of
the diamond
the abrasive grains on the diamond abrasive grinding wheel. The abrasive grains are
abrasive grinding wheel. The tip of the diamond pen aims at the high point of the abrasive
slightly broken. The grains
abrasive grains fall off due to the removal of the bond material.
on the diamond abrasive grinding wheel. The abrasive grains are slightly broken.
The abrasive grains fall off due to the removal of the bond material.

Figure 2. Schematic diagram

Figure 2.of diamond
Schematic pen dressing
diagram of diamonddiamond abrasive
pen dressing diamondgrinding wheel.wheel.
abrasive grinding

LEI et al. [5] set theLEI

diamond pen to grind each high point on the surface of the dia-
et al. [5] set the diamond pen to grind each high point on the surface of the
diamond abrasive grinding wheel to meet the grinding requirements of the diamond
mond abrasive grinding wheel
abrasive to wheel.
grinding meet When
the grinding requirements
using the diamond pen truingofmethod
the diamond
to dress theabra-
diamond
sive grinding wheel.abrasive
When grinding
using the diamond
wheel, penwheel
the grinding truing method
speed should to dress the at
be maintained diamond
a low speed,
abrasive grinding wheel, the itgrinding
otherwise, is difficultwheel
to achievespeed shoulddressing
the expected be maintained
effect. at a low speed,
Due to its simple structure and low investment cost, the diamond pen truing method
otherwise, it is difficult to achieve the expected dressing effect.
is widely used in the field of grinding, but the wear of the diamond pen is quite serious,
Due to its simple andstructure
the shape and lowand
accuracy investment
dimensional cost, the diamond
accuracy are not high,pen truing
which method
affects the surface
is widely used in theintegrity
field of grinding,
of diamond but the
abrasive weartools.
grinding of the
The diamond penroughness
grinding surface is quite (expressed
serious, as
and the shape accuracy and dimensional
Ra) gradually decreases with accuracy
increase inare not high,
dressing which3).affects
times (Figure When the thedressing
surfacetimes
reaches about 500 times, Ra tends to be stable [6], and the dressing efficiency is approxi-
integrity of diamondmately
abrasive grinding
30∼40%. tools.
Therefore, The have
scholars grinding
soughtsurface
to improveroughness
and develop (expressed
the traditional
as Ra) gradually decreases with increase in dressing times (Figure 3). When
diamond pen truing method which is organically integrated with other dressing the dressing
methods.
times reaches about For times, Ra
500example, tends
based to principle
on the be stable of [6], and the
vibration dressing
cutting, Zhao etefficiency is ap- an
al. [7,8] employed
proximately 30~40%.ultrasonic
Therefore, scholars have sought to improve and develop the tradi-
vibration dressing method together with a diamond pen. This technology could
eliminate the shortcomings of the traditional turning dressing of diamond pens and obtain
tional diamond pen good truing methodtowhich
morphology, achieveis theorganically integrated
purpose of improving withaccuracy
the shape other dressing
and grinding
methods. For example, based on
performance thegrinding
of the principlewheel,ofand
vibration cutting,
greatly improve Zhao et al. [7,8] em-
efficiency.
ployed an ultrasonic vibration dressing method together with a diamond pen. This tech-
nology could eliminate the shortcomings of the traditional turning dressing of diamond
pens and obtain good morphology, to achieve the purpose of improving the shape accu-
racy and grinding performance of the grinding wheel, and greatly improve efficiency.
 Appl. Sci. 2022, 12, x FOR PEER REVIEW 4

FOR PEER REVIEW

Appl. Sci. 2022, 12, 4683
4 of 224 of 21

Figure 3. Variation law of grinding surface roughness Ra with the dressing times [6].

3.1.2. Rolling Method

Figure 3. Variation law of 3.
Figure grinding
Variationsurface roughness
law of grinding Raroughness
surface with theRadressing times [6].
with the dressing times [6].
With a view to addressing the problems of the serious wear and tear of tools in
diamond
3.1.2. pen
Rolling truing method, the rolling method came into being. The diamond pen tr
Method
3.1.2. Rolling Method With a view to addressing the problems of the serious wear and tear of tools in the
method achieves the purpose of dressing according to the action of shearing force,
With a view totheaddressing
rolling
diamond themethod,
pen method
truing problems
mainly of themethod
the breaks
rolling serious
and lets wear
camefallintoand
the tear
Theof
abrasive
being. tools in
grains
diamond the
through
pen truingthe actio
diamond pen truing method,
method
pressure. the the
achieves
Figure rolling
4purpose
showsmethod cameaccording
of dressing
a schematic into being.
diagram to theThe diamond
ofaction
the pen
of shearing
rolling truing
force,
method, and the
in which a g
rolling method mainly breaks and lets fall the abrasive grains through the action of pressure.
method achieves the purpose
silicon4 shows
carbide of dressing
(SiC) or white according
corundum to the action
grinding of shearing force, and
Figure a schematic diagram of the rolling method, wheelin which isagenerally selected
green silicon carbideas the d
the rolling method(SiC)
ingmainly breaks
grinding and
wheel, andlets fall
the the
bottom abrasive
is a grains
diamond through
abrasive
or white corundum grinding wheel is generally selected as the dressing grinding the action
grinding of The diam
wheel.
pressure. Figure 4wheel,
showsand
abrasive agrinding
schematic
the bottom isdiagram
wheel is fixed
a diamond of abrasive
the rotated
and rolling method,
wheel.inThe
clockwise.
grinding which
The a green
dressing
diamond grinding whee
abrasive
silicon carbide (SiC)tates
grindingand reciprocates
or white corundum grinding
wheel is fixed and back and wheel
rotated forth through
clockwise.is generally
The the grinding
dressing selected as
grinding machine for and
the dress-
wheel rotates grinding. A
ing grinding wheel, and the bottom is a diamond abrasive grinding wheel. The diamond It can be
grinding
reciprocates by the
back rolling
and forth method,
through the
the diamond
grinding abrasive
machine for grains
grinding. are sharper.
After grinding
by the rolling method, the diamond abrasive grains are sharper. It can be seen from the
from the
abrasive grinding dressing
wheel dressing
isprinciple
fixed and principle clockwise.
that the rolling method has high requirements on the rig
thatrotated
the rolling method has The
highdressing
requirements grinding
on thewheel
rigidityro-
of the
of the
tates and reciprocates grinding
back
grinding and forth
machine. machine.through the grinding machine for grinding. After
grinding by the rolling method, the diamond abrasive grains are sharper. It can be seen
from the dressing principle that the rolling method has high requirements on the rigidity
of the grinding machine.

Figure4. 4.
Figure Schematic
Schematic diagram
diagram of theof the rolling
rolling method.method.

Drazumeric Radovan et al. [9] studied the lateral dressing of diamond abrasive g
ing wheels, which employed an Al2O3 or SiC dressing wheel to break and drop of
diamond
Figure 4. Schematic diagram of abrasive
the rollinggrains and shortened the dressing time under the condition of
method.
Appl. Sci. 2022, 12, x FOR PEER REVIEW
Appl. Sci. 2022, 12, 4683 5 of 21

tipsDrazumeric Radovan et al. [9] studied the lateral dressing of diamond abrasive grind-
of resin-bonded and metal-bonded diamond abrasive grinding wheels wit
ing wheels, which employed an Al2 O3 or SiC dressing wheel to break and drop off the
ing grinding
diamond abrasivewheels and
grains and found the
shortened that both kinds
dressing of diamond
time under abrasive
the condition grinding w
of constrain-
dressing
ing could
the dressing meet
force thethe
through requirements of microstructure
basic relationship between geometry, processing.
kinematics, andFigure 5
topography of the diamond abrasive grinding wheel surface after dressing by
the removal mechanism. Liang et al. [10] studied the tangential grinding of V-shaped
tips of resin-bonded and metal-bonded diamond abrasive grinding wheels with SiC dress-
method [11]. It was found that the diamond abrasive grains protruded from th
ing grinding wheels and found that both kinds of diamond abrasive grinding wheels
terial
after and had
dressing appropriate
could shape accuracy,
meet the requirements and the
of microstructure dressingFigure
processing. efficiency
5 showswas app
45~55%.
the topography of the diamond abrasive grinding wheel surface after dressing by the
rolling method [11]. It was found that the diamond abrasive grains protruded from
the bond material and had appropriate shape accuracy, and the dressing efficiency was
approximately 45∼55%.

Figure
Figure 5. 5. The
The micro-morphology
micro-morphology of the of the surface
surface of the diamond
of the diamond abrasive
abrasive grinding grinding
wheel after whee
ing [11].
dressing [11].

Some researchers have integrated the ultrasonic vibration dressing method into the
rollingSome
methodresearchers havequality
to achieve higher integrated the
grinding. ultrasonic
Wada et al. [12]vibration
designed a dressing
dressing meth
rolling
device formethod
truing andto achieve the
sharpening higher quality
grinding surfacegrinding.
of the diamondWada et al.grinding
abrasive [12] designed
device for truing and sharpening the grinding surface of the diamond
wheel by using an ultrasonic vibration device. Chen et al. [13] developed a method of using abrasi
“mid-frequency vibration-assisted grinding with self-induced grinding forces” to produce
wheel by using an ultrasonic vibration device. Chen et al. [13] developed a
micro-groove arrays on single crystal diamond (MCD) for super-hard material removal;
using
the “mid-frequency
experimental results showedvibration-assisted grinding
that there were no obvious burrswith self-induced
and cracks grindin
on the single
produce
crystal micro-groove
diamond, which could arrays on single grinding.
ensure high-quality crystal diamond (MCD) for super-ha
removal; the experimental results showed that
Although the rolling method has the above dressing there werethe
characteristics, noresidual
obviousbondburrs an
materials easily block the surface of the grinding wheel and reduce its grinding ability,
the single
which crystal
is the key diamond,
to restricting which could
the development ensure
of the rolling high-quality
method. grinding.
Although the rolling method has the above dressing characteristics, t
bond materials easily block the surface of the grinding wheel and reduce its gr
3.1.3. Grinding Method

ity,To
which is the key to restricting the development of the rolling method.
realize precision grinding and obtain a minimal amount of dressing removal, the
grinding method is applied to the dressing of diamond abrasive grinding tools. The
grinding method refers to the dressing of diamond abrasive grinding wheels with ordinary
3.1.3. Grinding
abrasive Method
grinding wheels. Grinding methods include the cup-shaped grinding wheel
truing method (this method solves the problems of flat abrasive surfaces and increased
To realize precision grinding and obtain a minimal amount of dressing r
grinding force during the dressing process), the low carbon steel or mild steel grinding
grinding
truing methodmethod
(due tois applied
a large numberto the dressing
of abrasive of diamond
grains falling off inabrasive
the truinggrinding
process, tools
iting method
is not suitable refers to the dressing
for high-precision of diamond
surface truing), abrasive
and diamond roller grinding wheels
truing. Figure 6 wi
abrasive grinding wheels. Grinding methods include the cup-shaped grinding
shows a schematic diagram of the grinding method dressing; the left side of Figure 6a
is a diamond abrasive grinding wheel and the right side is a dressing grinding wheel,
ing method (this method solves the problems of flat abrasive surfaces and incre
both of which rotate counterclockwise. Due to the difference in hardness between the two,
ing force during the dressing process), the low carbon steel or mild steel grin
method (due to a large number of abrasive grains falling off in the truing proc
suitable for high-precision surface truing), and diamond roller truing. Figure
schematic diagram of the grinding method dressing; the left side of Figure 6a is
 Appl. Sci. 2022, 12, 4683 6 of 21

when the dressing grinding wheel and the diamond abrasive grinding tool are ground
FOR PEER REVIEW 6 ofto22make
at the meshing position, the ordinary abrasive grains will cut the bond material
the abrasive grains fall off and meet the dressing requirements of the diamond abrasive
grinding wheel, as shown in Figure 6b.

Figure 6. Schematic diagram of grinding method dressing.

Lin [14] employed the high-speed rotating diamond roller to dress the diamond abra-
sive grinding wheel installed on the grinding machine. This method was simple to operate
and could improve the service life of the diamond abrasive grinding wheel. Zhang et al.
[15] conducted dressing experiments on coarse-grained and fine-grained bronze-bonded
diamond abrasive grinding wheels on a surface grinding machine with an abrasive water-
jet system and combined abrasive water-jet (AWJ) and contact dressing technology. It was
found that the dressing wheel could achieve less grinding force and better surface rough-
Figure 6. Schematic diagram of grinding method dressing.
ness. Zheng et al. [16]Figure
found that, compared
6. Schematic diagram with the
of grinding conventional
method dressing. scratch test, the scratch
force of the ultrasonic vibration-assisted method decreased
rotating significantly
diamond roller and the the
volume
Lin [14] employedLin the[14]
high-speed
employed the
rotating diamond
high-speed
roller to dress the diamond
to dress
abra-
diamond
of removed materials increased significantly. As shown in Figure 7 [17], after dressing simple
abrasive grinding wheel installed on the grinding machine. This method was by
sive grinding wheeltoinstalled on could
the grinding machine. This method was simple to operate
theand
grinding method,the
could improve the surfacelife
operate and ofofdiamond
improve abrasive grains
the service life of the was relatively
diamond abrasive smooth,
grinding the
wheel.
Zhangservice the diamond
et al. [15] conducted dressing abrasive
experiments grinding wheel. Zhang
on coarse-grained et al.
and fine-grained
edge
[15]angle was sharp,
conducted dressingtheexperiments
grinding
bronze-bonded edge
diamond was protruding,
on abrasive
coarse-grained andand
grinding wheels onthe dressing
fine-grained
a surface efficiency
machineof
bronze-bonded
grinding with
thediamond
grindingabrasive
methodgrinding
anwas approximately
abrasive water-jet system55~65%.
wheels on a surface grinding machine with an abrasive water-
and combined abrasive water-jet (AWJ) and contact dressing
The dressing process
jet system and combined of
technology. truing a diamond
It was found
abrasive abrasive
that the dressing
water-jet (AWJ)
wheelgrinding
and contact
could achievewheel
dressing by theforce
less grinding
technology. grinding
and better
It was
surface roughness. Zheng et al. [16] found that, compared with the conventional scratch test,
method
found is cumbersome
that the dressing and inefficient
wheel could and high-precision
achieve grinding surface
lessvibration-assisted
forcemethod
andtruing
bettercannot
surface berough-
carried
the scratch force of the ultrasonic decreased significantly and
out. Given the above
ness. Zheng et al. [16] problems,
the found
volumethat, researchers
compared
of removed have
with
materials proposed
the conventional
increased a series
significantly.scratch of
As shown new
test, processing
the scratch
in Figure 7 [17], after
methods,
force of such as the
the ultrasonicEDM truing
vibration-assisted
dressing by method
the grinding and the
method
method, laser truing
decreased
surface method,
significantly
of diamond hoping
abrasiveand to was
the
grains obtain
volume a
relatively
better dressingmaterials
of removed effect with highersignificantly.
increased
smooth, the edgeefficiency. As shown in Figure 7 [17], after dressing by
angle was sharp, the grinding edge was protruding, and the dressing
efficiency of the grinding method was approximately 55∼65%.
the grinding method, the surface of diamond abrasive grains was relatively smooth, the
edge angle was sharp, the grinding edge was protruding, and the dressing efficiency of
the grinding method was approximately 55~65%.
The dressing process of truing a diamond abrasive grinding wheel by the grinding
method is cumbersome and inefficient and high-precision surface truing cannot be carried
out. Given the above problems, researchers have proposed a series of new processing
methods, such as the EDM truing method and laser truing method, hoping to obtain a
better dressing effect with higher efficiency.

Figure 7. Surface condition

Figurebefore and
7. Surface after diamond
condition abrasive
before and after grinding
diamond abrasive[17].
grinding [17].

The dressing process of truing a diamond abrasive grinding wheel by the grinding
3.1.4. Electric Discharge Machining
method (EDM)
is cumbersome Truing Method
and inefficient and high-precision surface truing cannot be carried
EDM truing methods,
out. Givenincluding the electrolysis
the above problems, researchers method and athe
have proposed serieselectric spark
of new processing
methods, such as the EDM truing method and laser truing method, hoping to obtain a
method, are suitablebetter
for dressing a grinding wheel with a conductive material as a bond.
dressing effect with higher efficiency.
Among them, the electrolytic method refers to the dissolution and etching of metal bonds
through an electrolyte anode with the assistance of a formed cathode and mechanical fric-
tion. The7.electric
Figure spark method
Surface condition before refers
and aftertodiamond
the use abrasive
of electric corrosion
grinding [17]. to remove the bond
materials and diamond abrasive grains by use of a pulsed electric spark. Wu et al. [18]
carried out electrochemical
3.1.4. Electric machining
Discharge Machining (EDM)dressing
Truingon a multi-layer brazed coarse-grained
Method
Appl. Sci. 2022, 12, 4683 7 of 21

3.1.4. Electric Discharge Machining (EDM) Truing Method

EDM truing methods, including the electrolysis method and the electric spark method,
are suitable for dressing a grinding wheel with a conductive material as a bond. Among
them, the electrolytic method refers to the dissolution and etching of metal bonds through
an electrolyte anode with the assistance of a formed cathode and mechanical friction. The
electric spark method refers to the use of electric corrosion to remove the bond materials
and diamond abrasive grains by use of a pulsed electric spark. Wu et al. [18] carried
out electrochemical machining dressing on a multi-layer brazed coarse-grained diamond
abrasive grinding wheel containing a CMS electrolyte. This method could effectively
improve the machining surface quality. CMSs could increase the electrolytic capacity of
the electrolyte, enabling the wear abrasive particles to fall off smoothly, and reducing
the occurrence of processing defects, such as grinding surface breakage and cracks of the
diamond abrasive grinding wheel. Wang et al. [19] proposed a novel active gap capacitance
electric discharge machining (AGC-EDM) method for efficient machining of polycrystalline
diamond. Borisov et al. [20] discussed the electrochemical dressing method of diamond
abrasive grinding wheels and found that this method would not reduce the surface grinding
quality in the hybrid technology of electrochemical treatment. He et al. [21] studied the
electric-contact discharge after dressing to ensure the uniformity of the height of the
abrasive grain protrusion. Zhou et al. [22] found that the electric spark discharge current
affected the height of diamond abrasive grains protruding from the metal bond and the
size of the chip holding space and that the pulse width affected the surface roughness of
the diamond abrasive grinding wheel. Wang et al. [23] carried out EDM truing experiments
on the small ball-end fine diamond abrasive grinding wheel and analyzed the relationship
between the electrical parameters and contour accuracy; a reduction in the graphitization
of the diamond abrasive grinding wheels, and ideal dressing quality was achieved.
The surface effect of electric machining truing aluminum-based diamonds is shown in
Figure 8 [24]. It was found that the surface of the diamond abrasive grains was smooth and
bright, and the grinding edges were sharp. The EDM truing method had a high dressing
efficiency of approximately 60∼70% and had certain advantages in machining workpieces
that could not be machined by conventional machine tools, but it had disadvantages
in machining non-conductive materials. Moreover, the power supply of the electrolytic
machining method was expensive and the EDM truing method was difficult to process due
to the existence of a discharge gap. Especially for large abrasive grains, it was difficult to
process. Therefore, lasers began to be applied to truing diamond abrasive grinding tools.

Figure 8. Surface renderings of the aluminum-based diamond before and after Electrolytic in-process
dressing technology (ELID) processing [24].
 Appl. Sci. 2022, 12, 4683 8 of 21

3.1.5. Laser Truing Method

The laser truing method refers to adjusting the parameters of the focused laser and
controlling the position movement of the grinding wheel relative to the laser beam in
OR PEER REVIEW the three-dimensional mobile platform to make the laser directly irradiate the 8 ofdiamond
22
abrasive grinding tools. Through this non-contact processing method, the ideal geometric
accuracy can be obtained, and the grinding edges can be formed. Laser dressing of diamond
abrasive tools has attracted the attention and recognition of researchers at home and abroad
the key laser process
dueparameters to achieve
to its high processing betterhigh
efficiency, dressing
degree ofeffects. Chenand
automation, etreduced
al. [28]pollution
estab- [25].
lished a set of high-precision
Therefore, thelaser inspection
application of laserand tangential
technology dressing
in diamond V-shaped
abrasive grindingconcave
tools dressing
has become a hot topic in recent years.
diamond abrasive grinding wheel systems, took the fiber laser as the detection and dress-
Liu and others [26,27] found that the average power of fiber lasers and the overlap rate
ing equipment, adopted the spot
of the light digital
was image
roughly processing
proportional to technology, and controlled
the dressing efficiency the av-
and determined the key
erage error of the geometric
laser processparameters
parameters toof the V-shaped
achieve concave
better dressing effects. contour
Chen et al.to
[28]within 3% a set
established
with the optimization of process parameters.
of high-precision laser inspection and tangential dressing V-shaped concave diamond abra-
sive grinding wheel systems, took the fiber laser as the detection and dressing equipment,
With the development of laser technology, Cai et al. [29] employed the blowing as-
adopted the digital image processing technology, and controlled the average error of the
sisted dual laser (nanosecond and femtosecond
geometric parameters of the V-shaped laser) method
concave contourto dress the3%diamond
to within abra-
with the optimization
sive grinding tools,ofwhich could reduce
process parameters. the return of plasma particles generated after the
removal of bond gasification
With thetodevelopment
the surface of of the
laser grindingCaitool,
technology, et al.achieve the height
[29] employed of the
the blowing assisted
abrasive grains protruding from the bond and improve the grinding performance. This
dual laser (nanosecond and femtosecond laser) method to dress the diamond abrasive
grinding tools, which could reduce the return of plasma particles generated after the
method could also avoid the phase explosion effect, form the surface of diamond abrasive
removal of bond gasification to the surface of the grinding tool, achieve the height of the
grinding tools, quickly reduce
abrasive theprotruding
grains heat around fromthe the abrasive
bond and grains,
improveand reduce the
the grinding thermal This
performance.
damage defects of thermal
method couldcracks
alsoand
avoidgraphitization
the phase explosion on the surface
effect, form theofsurface
abrasive grains,abrasive
of diamond to
improve the dressing effect and the quality and accuracy of fine-machining. This study
grinding tools, quickly reduce the heat around the abrasive grains, and reduce the thermal
damage defects of thermal cracks and graphitization on the surface of abrasive grains, to
also had certain limitations. For example, the dual-laser device was more expensive than
improve the dressing effect and the quality and accuracy of fine-machining. This study also
the single-beam laser
hadand belonged
certain to aFor
limitations. process
example, method of rough
the dual-laser dressing
device diamond
was more expensiveabra-
than the
sive grinding tools.single-beam laser and belonged to a process method of rough dressing diamond abrasive
As shown in Figure
grinding9 tools.
[30], compared with blunt diamond abrasive grains, the dia-
mond abrasive grains after laserindressing
As shown hadcompared
Figure 9 [30], sharp grinding
with bluntedges
diamondand ideal grains,
abrasive shapethe accu-
diamond
abrasive grains after laser dressing had sharp grinding edges and ideal shape accuracy,
racy, while the dressing efficiency was approximately 70~80%.
while the dressing efficiency was approximately 70∼80%.

Figure 9. The micro-topography

Figure 9. The of the grinding wheel
micro-topography surfacewheel
of the grinding before andbefore
surface after laser dressing
and after [30]. [30].
laser dressing

Although laser truing of diamond abrasive grinding tools has the advantages of high
Although laserprecision
truing of diamond abrasive grinding tools has the advantages of high
and high efficiency, the diffusion of plasma after laser dressing, environmental
precision and high pollution,
efficiency, the
and thediffusion of plasma
establishment of a heatafter laser
transfer dressing,
model environmental
in the dressing process are still
pollution, and the establishment
difficult problemsoftoabe
heat transfer
considered andmodel
solved in the dressing
in subsequent process are still
development.
difficult problems to be considered and solved in subsequent development.

3.2. Sharpening Technology of Diamond Abrasive Grinding Tools

Sharpening technology of diamond abrasive grinding tools refers to the process of
Appl. Sci. 2022, 12, 4683 9 of 21

3.2. Sharpening Technology of Diamond Abrasive Grinding Tools

Sharpening technology of diamond abrasive grinding tools refers to the process of
cutting the excess bond material between the diamond abrasive grains, making them
possess appropriate chip holding space, making the grinding edge higher than the bond,
obtaining the ideal abrasive grain height, and forming the cutting edge. With the rapid
development of science and technology, the sharpening technology of diamond abra-
sive grinding tools has generated the free abrasive grain sharpening method, the con-
solidated dressing tool sharpening method, the EDM sharpening method, and the laser
sharpening method.

3.2.1. Free Abrasive Grain Sharpening Method

The free abrasive grain sharpening method mainly includes ultrasonic vibration
sharpening, free abrasive jet sharpening, and free abrasive extrusion sharpening. Among
these, the free abrasive jet sharpening method is a high-efficiency sharpening method,
which can obtain an ideal sharpening effect in a short time. Cui et al. [31] proposed
a dressing method combining grinding grains extrusion and dressing under the con-
straint of a diamond surface and found that this method could enable rapid forming and
precision dressing of super-hard abrasive grinding wheels. When selecting appropriate
parameters, such as the grinding force and grinding ratio, the dressing efficiency was
approximately 23∼30%.
To improve the surface topography characteristics of abrasive tools and achieve the
purpose of dressing, numerous researchers have used the ultrasonic vibration sharpening
method in combination with other methods. Soleimanimehr et al. [32] studied the ultrasonic
vibration dressing method and analyzed the influence of the cutting ratio on the diameter
error in ultrasonic vibration-assisted turning. Yang et al. [33] carried out a laser ultrasonic
vibration collaborative dressing experiment on diamond abrasive grinding wheels and
studied the removal behavior of laser-assisted ultrasonic dressing of diamond abrasive
grinding wheel material through simulation and experimental methods. The experiments
showed that the simulation results could be used effectively for the selection of process
parameters. The abrasive grains had an ideal shape and protrusion in this dressing mode,
and the grinding wheel had a large chip holding space.
The efficiency of dressing diamond abrasive grinding tools by the free abrasive grain
sharpening method is low, so it has not been popularized and applied in industrial produc-
tion. However, the integration of the ultrasonic vibration sharpening method and other
dressing methods is still a worthwhile research direction for future dressing technology.

3.2.2. Consolidated Dressing Tool Sharpening Method

Consolidation dressing tool sharpening methods include the oilstone sharpening
method, the ordinary grinding wheel grinding sharpening method, and the silicon carbide
(SiC), or corundum block cutting sharpening method. These methods mainly utilize the
difference in hardness between the sharpening tool and the diamond abrasive grains to
make the abrasive grains fall off by cutting the bond material between the abrasive grains.
The dressing effect is shown in Figure 10 [34]. Klink et al. [35] employed internal cooling
grinding tools and an electric corrosion process to dress the abrasive grains, which could
achieve the ideal sharpening effect. Zhou et al. [36] dressed the diamond abrasive grinding
wheel through three-axis linkage circular arc interpolation movement, which had a simple
structure, high dressing accuracy, and high processing efficiency. Chen et al. [37] used
three-axis linkage machine tools and sharpening tools, such as carbide grinding rods, to
dress resin-bonded V-shaped diamond abrasive grinding wheels to achieve accurate in
situ dressing. Xue [38] designed a twist drilling device for dressing diamond abrasive
grinding wheels with a large dressing area, high efficiency, and high accuracy. Liu et al. [39]
employed oilstone as a grinding tool to remove the bond material of the diamond abrasive
grinding wheel and drove the oilstone to dress the end face of the grinding wheel by
 Appl. Sci. 2022, 12, 4683 10 of 21

OR PEER REVIEW 10 of 22
rotating the dressing shaft. This design was effective, low cost, and showed an ideal
dressing effect.

Figure 10. Comparison of 10.

Figure grinding wheel
Comparison surfacewheel
of grinding morphology before and
surface morphology after
before grinding
and after wheel
grinding wheel
dressing [34]. dressing [34].

Through the above research at home and abroad, it was found that, compared with
Through the above
the freeresearch at home
abrasive grain and abroad,
sharpening method, it
thewas found
dressing that, compared
efficiency with
of the consolidated
the free abrasive grain sharpening method, the dressing efficiency of the consolidated
dressing tool sharpening method was improved to a certain extent, by approximately
35∼45%. The surface roughness of the grinding wheel after sharpening was reduced and
dressing tool sharpening method
a large number was
of new improved
abrasive to a exposed.
grains were certain Although
extent, by some approximately
progress has been
35~45%. The surface made in the consolidation dressing tool sharpening method, it cannot reduced
roughness of the grinding wheel after sharpening was be used forand
large
a large number of new abrasive
cutting quantitiesgrains
and the were exposed.
sharpening Although
efficiency some
is low. This is stillprogress hasneeds
an aspect that beento
be improved in the development of the consolidation dressing tool sharpening method in
made in the consolidation dressing tool sharpening method, it cannot be used for large
the future.
cutting quantities and the sharpening efficiency is low. This is still an aspect that needs to
be improved in the3.2.3.
development of theMachining
Electric Discharge consolidation dressing tool
(EDM) Sharpening sharpening method in
Method
the future. EDM sharpening methods mainly include the EDM dressing method and the elec-
trolytic online dressing method. EDM grinding wheel dressing technology was first pro-
posed by Suziki et al. [40]. Figure 11 shows a schematic diagram of the EDM dressing
3.2.3. Electric Discharge Machining
technology. The diamond(EDM) Sharpening
abrasive Method
grinding tool rotates clockwise and is connected to the
EDM sharpening methods mainly include the EDM dressing
positive pole of the power supply, while the tool electrode methodtoand
is connected the elec-
the negative pole
of the power supply. The discharge medium, such as working fluid, is introduced between
trolytic online dressing method.
the diamond EDMgrinding
abrasive grinding wheel
wheel dressing
and the technology
tool electrode to makewas firstvoltage
the pulse pro-
posed by Suziki etpassal. through,
[40]. Figure
thereby 11generating
shows aa schematic
pulsed sparkdiagram
and forming of athe EDMchannel.
discharge dressing The
technology. The diamond
phenomenonabrasive grinding
of electric corrosiontool rotates
eliminates theclockwise
bond materialandandisachieves
connected to theof
the purpose
positive pole of the power supply, while the tool electrode is connected to the negative
sharpening the diamond abrasive grinding wheel. Yu et al. [41] conducted experimental
research on EDM dressing of the bronze-bonded diamond abrasive grinding wheel using
pole of the power supply.
an internalThe
impactdischarge
arc copper medium, such and
tungsten electrode as working fluid,
found that the is introduced
surface abrasive grains
between the diamond wereabrasive
prominent,grinding wheel
large in number, and
and highthe tool electrode to make the pulse
in density.
voltage pass through, thereby generating
Electrolytic in-process adressing
pulsedtechnology
spark and forming
(ELID) a discharge
was developed channel.
in Japan in the
early 1990s for precision mirror grinding of dressing grinding wheels. Figure 12 shows a
The phenomenon of electric corrosion eliminates the bond material and achieves the pur-
schematic diagram of the electrolytic in-process dressing technology. The working principle
pose of sharpeningofthe diamond
ELID abrasive
is to use tool grinding
electrodes wheel.abrasive
and diamond Yu et grinding
al. [41] conducted
wheels as cathodeexper-and
imental research on EDM
anode, whiledressing
the nozzle ofsprays
the bronze-bonded diamond
special electrolytic grinding fluidabrasive
between the grinding
two poles.
wheel using an internal
Under impact
the actionarc copper
of the powertungsten
supply, theelectrode and found
diamond abrasive thatwheel
grinding the surface
is dressed
online through the anode dissolution effect. When the bond material is eroded, a layer of
abrasive grains were prominent,
dense oxide film large
is formedin number, andofhigh
on the surface in density.
the grinding wheel, which can slow down
the electrolysis speed, prevent excessive electrolysis and avoid excessive wear of the
grinding wheel. However, as the oxide film becomes thinner and the conductivity increases,
the electrolysis speed of the bond materials is accelerated to realize the cycle of online
 Appl. Sci. 2022, 12, 4683 11 of 21

electrolytic sharpening. During the sharpening process, the surface of the grinding wheel
can maintain the most ideal morphology and achieve ultra-precision mirror grinding. Chen
Figure 11. Schematic diagram
et al. [42] of electrican
proposed spark dressing technology.
ultrasonic-assisted electrolytic process sharpening method, which
combined the high-frequency ultrasonic vibration method with the electrolytic method in
Electrolytic in-process
parallel and dressing technology
carried out comparative (ELID) was on
experiments developed
this. It wasin Japan
found thatin
thethe
method
could improve the removal rate and machining surface quality and overcome the difficulty
early 1990s for precision
Appl. Sci. 2022, 12, x FOR PEER REVIEW
mirror grinding of dressing grinding wheels. Figure 12 shows a
of continuous dressing of the fine diamond abrasive grinding wheel in the machining
schematic diagram process.
of the electrolytic
Kundrák et al.in-process dressing
[43] found that technology.
electrochemical The could
machining workingremoveprin-
the metal
ciple of ELID is to use
bond tool electrodes
to make abrasiveand diamond
grains protrude abrasive grinding
and maintain wheels
their cutting as cathode
ability.
and anode, while the nozzle sprays special electrolytic grinding fluid between the two
poles. Under the action of the power supply, the diamond abrasive grinding wheel is
dressed online through the anode dissolution effect. When the bond material is eroded, a
layer of dense oxide film is formed on the surface of the grinding wheel, which can slow
down the electrolysis speed, prevent excessive electrolysis and avoid excessive wear of
the grinding wheel. However, as the oxide film becomes thinner and the conductivity in-
creases, the electrolysis speed of the bond materials is accelerated to realize the cycle of
online electrolytic sharpening. During the sharpening process, the surface of the grinding
wheel can maintain the most ideal morphology and achieve ultra-precision mirror grind-
ing. Chen et al. [42] proposed an ultrasonic-assisted electrolytic process sharpening
method, which combined the high-frequency ultrasonic vibration method with the elec-
trolytic method in parallel and carried out comparative experiments on this. It was found
that the method could improve the removal rate and machining surface quality and over-
come the difficulty of continuous dressing of the fine diamond abrasive grinding wheel
in the machining process. Kundrák et al. [43] found that electrochemical machining could
remove the metal bond to make abrasive grains protrude and maintain their cutting abil-
ity. Figure
Figure 11.11. Schematic
Schematic diagram
diagram of electric
of electric sparktechnology.
spark dressing dressing technology.

Electrolytic in-process dressing technology (ELID) was developed in Japa

early 1990s for precision mirror grinding of dressing grinding wheels. Figure 12
schematic diagram of the electrolytic in-process dressing technology. The worki
ciple of ELID is to use tool electrodes and diamond abrasive grinding wheels as
and anode, while the nozzle sprays special electrolytic grinding fluid between
poles. Under the action of the power supply, the diamond abrasive grinding
dressed online through the anode dissolution effect. When the bond material is e
layer of dense oxide film is formed on the surface of the grinding wheel, which c
down the electrolysis speed, prevent excessive electrolysis and avoid excessive
the grinding wheel. However, as the oxide film becomes thinner and the conduc
creases, the electrolysis speed of the bond materials is accelerated to realize the
online electrolytic sharpening. During the sharpening process, the surface of the
wheel can maintain the most ideal morphology and achieve ultra-precision mirro
Figure 12. Schematic diagram
Figure 12. of electrolytic
Schematic in-process
diagram dressing
of electrolytic technology.
in-process dressing technology.
ing. Chen et al. [42] proposed an ultrasonic-assisted electrolytic process sha
method,
Figure which
13 shows combined
a comparison theofhigh-frequency
the grinding wheel ultrasonic vibration
surface before method
and after EDM with
trolytic method in parallel and carried out comparative experiments onthe
dressing [44]. It can be seen from the figure that the grinding wheel surface after this. It w
that the method could improve the removal rate and machining surface quality a
dressing is smooth and flat, the outer contour is clear and has a sharp cutting edge.
The research showed that the dressing efficiency of the EDM sharpening method was
come the difficulty50of
high—approximately continuous
∼60%. dressing
After dressing, of theoffine
the surface diamond
the abrasive abrasive
grinding tool grindin
in the
had chipmachining
space, and theprocess.
abrasiveKundrák
protrudinget al. [43]
bond found
height that electrochemical machini
was ideal.
remove the metal bond to make abrasive grains protrude and maintain their cutt
ity.
 Figure 13 shows a comparison of the grinding wheel surface before and aft
dressing [44]. It can be seen from the figure that the grinding wheel surface after th
ing is smooth and flat, the outer contour is clear and has a sharp cutting edge. The
showed that the dressing efficiency of the EDM sharpening method was high—a
Appl. Sci. 2022, 12, 4683 mately 50~60%. After dressing, the surface of the abrasive grinding 12 tool
of 21had chi

and the abrasive protruding bond height was ideal.

Figure
Figure 13.13.
TheThe surface
surface condition
condition of the grinding
of the grinding wheel afterwheel
electricafter electric
machining [44].machining [44].

Although the EDM dressing method, the electrolytic in-process dressing method,
Although the EDM dressing method, the electrolytic in-process dressing me
or other compound EDM dressing methods can better achieve the precision dressing
other
of compound
diamond abrasive EDM dressing
grinding methods
tools, their can better
disadvantages, suchachieve the precision
as high cost, insufficientdressin
mond abrasive
environmental grinding
protection, andtools,
easy totheir
formdisadvantages,
thermal damage, such
restrictasthe
high cost, insufficient
development of e
mental protection, and easy to form thermal damage, restrict the development
their technology.
technology.
3.2.4. Laser Sharpening Method
Figure 14 shows a schematic diagram of the laser sharpening diamond abrasive
3.2.4. Laser
grinding Sharpening
tool. Its Method
working principle is that the laser beam, with a certain power density, is
Figure
directly 14 on
irradiated shows a schematic
the diamond abrasivediagram of as
grinding tool the laser sharpening
a “processing tool”, anddiamond
the
surface temperature of the grinding tool rises rapidly. Using the difference between the
grinding tool. Its working principle is that the laser beam, with a certain power de
melting point of the bond material and the diamond abrasive grains, the bond material is
directly
heated, irradiated
melted, on the
and gasified, diamond
then separatedabrasive grinding
from the diamond tool as
abrasive a “processing
grinding wheel in tool”,
asurface
gaseous temperature
or plasma state of the grinding
to achieve toolofrises
the purpose rapidly. Using the difference betw
sharpening.
melting point of the bond material and the diamond
At the end of the 20th century, Westkämper [45] of abrasive grains,
the University the bond m
of Brunswick
in Germany, first proposed the application of laser technology to the dressing of super-
heated, melted, and gasified, then separated from the diamond abrasive grindin
hard abrasive grinding tools. Deng et al. [46] carried out laser ablation experiments on
in a gaseous
resin-bonded or plasma
diamond state
abrasive to achieve
grinding wheelsthe purpose
based of sharpening.
on the nanosecond laser dressing
process parameters to realize low-damage and ultra-precision dressing of the resin-bonded
diamond abrasive grinding wheels and proposed a new laser dressing method based on
layered scanning to solve the problem of the degradation of abrasive performance caused
by ablation heat. Witt T [47] irradiated the pulsed laser on the surface of diamond abrasive
grinding tools, which could obtain ideal abrasive grain protrusion height and cutting
of the abrasive grain binding force. Our team [48–50] studied the theory and numerical
modeling of plasma isothermal expansion produced by nanosecond laser ablation of bronze-
bonded diamond abrasive grinding wheels and deduced the dynamic equation of plasma
expansion, which could provide a reference for future research on plasma characteristics. A
new method of dressing bronze-bonded diamond abrasive grinding wheels with water-
column-flow-assisted pulsed fiber laser was proposed. The ideal dressing effect was
obtained through the dressing test, as shown in Figure 15, which was of significance for
optimization of the dressing process.
Appl. Appl.
Sci. 2022, 12,12,
Sci. 2022, x FOR
4683 PEER REVIEW 13 of 21

Figure 14. Schematic diagram of laser dressing diamond abrasive grinding wheel.

At the end of the 20th century, Westkämper [45] of the University o

Germany, first proposed the application of laser technology to the dressing
abrasive grinding tools. Deng et al. [46] carried out laser ablation experim
bonded diamond abrasive grinding wheels based on the nanosecond lase
cess parameters to realize low-damage and ultra-precision dressing of th
diamond abrasive grinding wheels and proposed a new laser dressing me
layered scanning to solve the problem of the degradation of abrasive perfo
by ablation heat. Witt T [47] irradiated the pulsed laser on the surface of dia
grinding tools, which could obtain ideal abrasive grain protrusion height
the abrasive grain binding force. Our team [48–50] studied the theory and n
eling of plasma isothermal expansion produced by nanosecond laser abla
bonded diamond abrasive grinding wheels and deduced the dynamic equa
expansion, which could provide a reference for future research on plasma
A new method of dressing bronze-bonded diamond abrasive grinding whe
column-flow-assisted pulsed fiber laser was proposed. The ideal dressing
tained through the dressing test, as shown in Figure 15, which was of s
optimization
Figure of the
14. Schematic dressing
diagram process.
of laser dressing diamond abrasive grinding wheel.
Figure 14. Schematic diagram of laser dressing diamond abrasive grinding wheel.

At the end of the 20th century, Westkämper [45] of the University of Brun
Germany, first proposed the application of laser technology to the dressing of sup
abrasive grinding tools. Deng et al. [46] carried out laser ablation experiments o
bonded diamond abrasive grinding wheels based on the nanosecond laser dress
cess parameters to realize low-damage and ultra-precision dressing of the resin
diamond abrasive grinding wheels and proposed a new laser dressing method b
layered scanning to solve the problem of the degradation of abrasive performance
by ablation heat. Witt T [47] irradiated the pulsed laser on the surface of diamond
grinding tools, which could obtain ideal abrasive grain protrusion height and cu
the abrasive grain binding force. Our team [48–50] studied the theory and numeric
eling of plasma isothermal expansion produced by nanosecond laser ablation of
bonded diamond abrasive grinding wheels and deduced the dynamic equation o
expansion,
Figure
Figure whichand
15. Topography could
15. Topography provide
and
landform of a reference
landform
bronze for diamond
of bronze
diamond future
abrasive research
grinding abrasive
wheel onmulti-pulse
after plasma charac
grinding wheel
Afiber
new
fiber method
laser
laser of dressing bronze-bonded diamond abrasive grinding wheels wit
dressing.
dressing.
column-flow-assisted pulsed fiber laser was proposed. The ideal dressing effect
Through the above-mentioned domestic and foreign research, it was found that the
tained through
diamond the dressing
abrasive grains, test, as shown
after laser sharpening, in Figure
protruded 15, of
by one-third which wasofof
the height thesignific
optimization
bond, of the
there was chip dressing
holding space process.
around the abrasive grains, and the dressing efficiency
was approximately 80∼88%.

4. Numerical Simulation and Experimental Research on Laser Dressing Bronze

Diamond Abrasive Grinding Wheels
Dressing diamond abrasive grinding tools is mainly divided into two steps: truing
and sharpening. Among the truing methods, the laser truing method has the highest
efficiency—approximately 70∼80%. Similarly, the dressing efficiency of the laser sharpen-
ing method ranks first among all sharpening methods at approximately 80∼88%. Laser
Appl. Sci. 2022, 12, 4683 14 of 21

processing is a comprehensive, efficient, and green dressing method. Therefore, numerical

simulation analysis and related experimental research have been carried out for the method
of laser dressing of diamond abrasive grinding tools.
When a pulsed fiber laser is vertically incident on the surface of a bronze-bonded
diamond abrasive grinding wheel, a variety of complex physical phenomena are involved,
such as serial energy superposition and the accumulation effect. Different from the contin-
uous laser, the working mode of the pulsed laser is to produce a laser output at a certain
interval. After the end of the previous pulse, except for a small part of the heat trans-
ferred to the air, most of the heat is deposited in the bronze-bonded diamond abrasive
grinding wheel and provides energy for the next laser pulse to reach the surface of the
grinding wheel. With the superposition of laser pulses, the laser energy accumulates
in the bronze-bonded diamond abrasive grinding wheel layer by layer, which affects its
ablation threshold. When considering the effect Q of the optical fiber laser pulse energy
accumulation on the bronze-bonded diamond abrasive grinding wheel in the literature [3],
it is only regarded as a simple superposition of θ times of pulse energy, and the calculation
expression is:

S 1 − Sθ
Q= (1)
1−S
where S is the energy accumulation coefficient of bronze material, θ is the number of laser
pulses, and the numerical value is 12. Equation (1) shows that S% of each laser pulse energy
is accumulated in the bronze diamond grinding wheel, and when the grinding wheel is
irradiated for the last time (the θ time), the θ-1 pulse energy previously stored on the surface
of the bronze-bonded diamond abrasive grinding wheel will all be converted to the last
(the θ time) incident laser pulse energy. However, since the laser energy decay process
follows an exponentially decreasing law [51,52], when establishing the heat transfer model,
the serial energy superposition and accumulation effect QC is regarded as the exponential
form. Compared with the simple superposition, it is more in line with the objective law
and easy to calculate; its calculation expression is:
1
√2
Sθ
QC = e 3 (2)

In summary, considering the superposition accumulation effect of the serial energy

QC in the process of dressing the bronze-bonded diamond abrasive grinding wheels by a
pulsed fiber laser, the relevant heat transfer model is established based on the Fourier heat
transfer model as follows:
  1
∂ ∂Tl −bx √2
Sθ
ρl cl = k + bβe I0 (t)e 3 (0 ≤ t ≤ τ, 0 ≤ x ≤ S(t)) (3)
∂x l ∂x

where subscript l indicates that the material is in the liquid phase, k is the thermal con-
ductivity, b is the absorption rate of bronze material, β is the absorption speed of bronze
material, x is the depth of the laser dressing bronze diamond abrasive grinding wheel, and
I0 (t) is the laser energy density of the Gaussian incident laser; its calculation expression is:

2
t − τ2
I0 (t) = I0 exp(− ) (4)
2σ2
where I0 is the peak value of the pulsed laser energy density, τ is the laser pulse width, and
σ is a parameter that can change the time shape of the laser pulse.
Set the initial condition as approximately 300 K at room temperature, and establish
the boundary conditions as follows:

T |t=0 = 300 K (5)

Appl. Sci. 2022, 12, 4683 15 of 21

∂T
−k = βI0 (t) (0 ≤ t ≤ τ ) (6)
∂t
∂T
−k =0 (0 ≤ t ≤ τ ) (7)
∂x x =d
The finite difference equations for Equation (3) and boundary conditions (Equations (5)–(7))
are established as follows:
j +1 j j j j
2 ! !
Ti − Ti Ti+1 − 2Ti + Ti−1 −bi∆x j∆t − τ2 Sθ 1/2
ρl cl = kl + bβe I0 exp − exp √ (8)
∆t (∆x )2 2σ2 3

j j
!
T1 − T0 ( j∆t − τ/2)2
−k = βI0 exp − (0 ≤ t ≤ τ ) (9)
∆x 2σ2
j
Td = 0; Ti0 = 300 K (10)
After finishing, we can obtain:

!
2 ! !
j +1 k∆t j 2k∆t j k∆t j ∆t j∆t − τ2 Sθ 1/2
Ti = T
2 i +1
+ 1− Ti + T
2 i −1
+ bβe−bi∆x I0 exp − exp √ (11)
ρc(∆x ) ρc(∆x )2 ρc(∆x ) ρc 2σ2 3

k∆t
Establish the grid Fourier number F01 = , and convert Equation (9) into:
ρc(∆x )2

2 ! !
j +1 j j j ∆t j∆t − τ2 Sθ 1/2
Ti = F01 Ti+1 + (1 − 2F01 ) Ti + F01 Ti−1 + bβe−bi∆x I0 exp − exp √ (12)
ρc 2σ2 3

The thermophysical parameters of the bronze and diamond and the calculation pa-
rameters are shown in Tables 1 and 2.
Table 1. Thermophysical parameters of the bronze and diamond.

Material Name Symbol Unit Numerical Value

Atomic mass m kg 1.038 × 10−25
Density ρs kg·m−3 8620
Melting temperature Tm K 1173
Gasification temperature Tl K 2770
Bronze
Thermal diffusivity k cm2 ·s−1 0.14
Thermal conductivity ks W ·m−1 ·K−1 41.9
Specific heat capacity cs J·kg−1 ·K−1 352
Absorption rate β — 0.38
Density ρs kg·m−3 3.52
Melting temperature Tm K 3550
Gasification temperature Tl K 4830
Refractive index n — 2.42
Diamond
Thermal diffusivity k cm2 ·s−1 3.11
Thermal conductivity ks W ·m−1 ·K−1 2000
Specific heat capacity cs kg−1 ·K−1 1827
Absorption rate β — 0.25

Table 2. Calculation parameters.

Name Symbol Unit Numerical Value

Laser wavelength λ nm 1064
Electron mass me kg 9.1 × 10−31
Average ionization energy U eV 7.63
Appl. Sci. 2022, 12, 4683 16 of 21

Table 2. Cont.

Name Symbol Unit Numerical Value

Pulse repetition rate f kHz 50
Energy accumulation coefficient s — 0.85
Spot diameter D µm 38
Pulse width τ ns 210
Absorption coefficient b m−1 4.76 × 106
Boltzmann constant kb J ·K−1 1.38 × 10−23
Grinding machine speed rv r·min−1 300

Set the laser power density to be 1.68 × 108 W/cm2 , 2.52 × 108 W/cm2 and
3.36 × 108 W/cm2 . Calculation parameters combining the thermophysical parameters
(Table 1) and the calculated parameters (Table 2) for bronze and diamond are shown
in Table 3.
Table 3. Combined calculation parameters.

Numerical Value
Name Unit
Bronze Diamond
Laser ablation time min 6 6
Number of cycles times 3 3
Pulse width ns 210 210
Distance in the X-direction µm 16 4.8
Time step ns 0.21 0.021
Spatial step µm 1 0.12
k∆t/(ρc(∆x)2 ) — 0.0029 0.4541

Since k∆t/(ρc(∆x)2 ) is less than 0.5 for both the bronze and diamond cases, the nu-
merical solution is stable and convergent. The temperature evolution law of the bronze
bond and diamond abrasive grains dressed by pulsed fiber laser was obtained by computer
programming through MATLAB, as shown in Figure 16.
The temperature change of pulsed fiber laser dressing bronze material is shown in
Figure 16a. When the laser power density reached 1.68 × 108 W/cm2 , the maximum
temperature of the bronze material was approximately 4400 K, which was higher than the
gasification temperature of bronze (2770 K). The solid-phase bronze material can be directly
gasified in one laser pulse to remove the excess bronze bond and realize the purpose of
sharpening the bronze-bonded diamond abrasive grinding wheel.
Figure 16b–d shows the temperature change of pulsed fiber laser dressing diamond.
When the laser power density was 1.68 × 108 W/cm2 , as shown in Figure 16b, the maximum
temperature of the diamond surface after the dressing was approximately 3800 K, which
was slightly higher than the melting point temperature of diamond (3550 K). Due to the
short dressing time of the pulsed laser, the laser energy had little effect on the diamond
abrasive grains and they maintained their original shape. When the laser power density
increased to 2.52 × 108 W/cm2 , as shown in Figure 16c, the maximum temperature of the
diamond surface reached 5900 K, which was higher than the gasification temperature of
the diamond (4830 K). At this point, the laser energy can gasify the diamond in a short
time, therefore the diamond abrasive grains were obviously deformed, and the truing effect
of the diamond abrasive grinding tools was achieved. With gradual increase in the laser
power density to 3.36 × 108 W/cm2 , as shown in Figure 16d, the maximum temperature
of the diamond surface was as high as 7850 K. Excessive laser energy can lead to a large
amount of diamond removal. However, due to the short time of pulsed fiber laser dressing
of the bronze-bonded diamond abrasive grinding wheel, only part of the diamond will be
removed, leaving large or small pits on its surface.
 Appl. Sci. 2022, 12, x FOR PEER REVIEW 17 of 22

temperature of the diamond surface was as high as 7850 K. Excessive laser energy can
lead to a large amount of diamond removal. However, due to the short time of pulsed
Appl. Sci. 2022, 12, 4683 17 of 21
fiber laser dressing of the bronze-bonded diamond abrasive grinding wheel, only part of
the diamond will be removed, leaving large or small pits on its surface.

Figure 16. Temperature changes in the pulsed fiber laser dressing bronze material and diamond. (a)
Figure 16. Temperature changes in the pulsed fiber laser dressing bronze material and diamond.
Bronze material, laser power density: 1.68 × 108 W/cm2; 8(b) Diamond, laser power density: 1.68 × 108
2 ; (b) Diamond, laser power density:
(a) Bronze material, laser power density: 1.68 × 10 W/cm
W/cm2; (c) Diamond, laser power density: 2.52 × 108 W/cm 2; (d) Diamond, laser power density: 3.36
108 W/cm
× 108×W/cm
1.68 2.
2 ; (c) Diamond, laser power density: 2.52 × 108 W/cm2 ; (d) Diamond, laser power

density: 3.36 × 108 W/cm2 .

Figure 17 shows the experimental equipment for laser dressing the bronze-bonded
diamond
Figureabrasive
17 showsgrinding wheels. In theequipment
the experimental experiment, forthe wavelength
laser dressingof the the fiber laser
bronze-bonded
was 1064 nm, the pulse frequency was 50 kHz, the pulse width was 210 ns, and three
diamond abrasive grinding wheels. In the experiment, the wavelength of laserlaser
the fiber
power densities of 1.68 × 10 W/cm , 2.52 × 10 W/cm , and 3.36 × 10 W/cm were selectedthree
was 1064 nm, the pulse frequency
8 2 was 50 8kHz, the
2 pulse width
8 was 2210 ns, and
for the
laser dressing
power experiment.
densities of 1.68As×can108beW/cm 2 , 2.52 × 108 W/cm2 , and 3.36 × 108 W/cm2
seen from Figure 17, the single-mode optical fiber
was focused
were selectedbyfor
a lenticular
the dressinglens experiment.
with a focal length
As canofbe 180 mmfrom
seen inside the pulsed
Figure 17, thelaser
single-
ablation
mode head,fiber
optical and was
then focused
the surfaceby aon the bronze-bonded
lenticular lens with adiamond abrasive
focal length of 180grinding
mm inside
wheel
the was vertically
pulsed irradiated;
laser ablation head, theand
defocus
thenamount was 0.on
the surface During the laser dressingdiamond
the bronze-bonded pro-
cess, the grinding
abrasive bronze-bonded
wheeldiamond abrasive
was vertically grindingthe
irradiated; wheel (model
defocus is 100D
amount was× 10T × 5X × the
0. During
31.75H
laser × 80#) was
dressing fixed on
process, thethebronze-bonded
surface grindingdiamond
machine and was driven
abrasive by the
grinding main(model
wheel shaft is
Appl. Sci. 2022, 12, x FOR PEER REVIEW 18 of 22
to rotate
100D counterclockwise
× 10T × 5X × 31.75H at a×speed
80#) of
was300fixed
r/min.on the surface grinding machine and was
driven by the main shaft to rotate counterclockwise at a speed of 300 r/min.

Figure17.
Figure 17. Laser
Laser dressing
dressing the
the bronze-bonded
bronze-bondeddiamond
diamondabrasive
abrasivegrinding
grindingwheel
wheelexperimental
experimentalequipment.
equip-
ment.

The surface topography of the bronze-bonded diamond abrasive grinding wheel ab-
lated by pulsed fiber laser was photographed with a three-dimensional ultra-depth-of-
field microscope under magnification (200 times). Through observation, it was found that
the topography of the bronze-bonded diamond abrasive grinding wheel dressed by dif-
ferent laser power density was different.
 ment.

The surface topography of the bronze-bonded diamond abrasive grinding wheel ab-
lated by pulsed fiber laser was photographed with a three-dimensional ultra-depth-of-
Appl. Sci. 2022, 12, 4683 18 of 21
field microscope under magnification (200 times). Through observation, it was found that
the topography of the bronze-bonded diamond abrasive grinding wheel dressed by dif-
ferent laser power density was different.
The surface topography of the bronze-bonded diamond abrasive grinding wheel
Figure 18a shows the surfacefiber
ablated by pulsed topography of the bronze-bonded
laser was photographed diamond ultra-depth-
with a three-dimensional abrasive
of-field microscope under magnification (200 times).8 Through observation, it was found
grinding wheel when thetopography
that the laser power density
of the was 1.68
bronze-bonded × 10 abrasive
diamond W/cm .grinding
2 At thiswheel
time,dressed
the ab- by
lation threshold ofdifferent
the bronze bond
laser power material
density had been reached and the removal of the
was different.
bronze material had been Figurerealized.
18a shows There was almost
the surface topography no of
change in the diamond
the bronze-bonded diamond abrasive
abrasive
8 2
grinding wheel when the laser power density was 1.68 × 10 W/cm . At this time, the
grains and the dressing effect was slight. Figure 18b shows the surface topography of the
ablation threshold of the bronze bond material had been reached and the removal of the
bronze-bonded diamond abrasive
bronze material hadgrinding wheel
been realized. Therewhen the laser
was almost power
no change density
in the diamond was 2.52
abrasive
× 10 W/cm . The grains
8 2 morphology of theeffect
and the dressing diamond abrasive
was slight. grains
Figure 18b shows changed
the surfacesignificantly,
topography of
showing a sharp grinding8 edge. 2The removal rate of the bronze material was density
the bronze-bonded diamond abrasive grinding wheel when the laser power high, thewas
2.52 × 10 W/cm . The morphology of the diamond abrasive grains changed signifi-
height of the diamond abrasive grains protruding from the bronze bond was ideal, and a
cantly, showing a sharp grinding edge. The removal rate of the bronze material was high,
certain chip-holding the space
height ofwas
the reserved. Whengrains
diamond abrasive the laser power
protruding was
from the increased
bronze bondto was3.36 ×
ideal,
10 W/cm , as shown
8 2 andin Figurechip-holding
a certain 18c, graphitization occurred
space was reserved. on the
When surface
the laser powerof was
the increased
diamondto
8 W/cm2 , as shown in Figure 18c, graphitization occurred on the surface of
abrasive grains after dressing, and part of the surface had deep or shallow depressions
3.36 × 10
the diamond abrasive grains after dressing, and part of the surface had deep or shallow
and cracks. depressions and cracks.

Figure 18. Topography Figureof 18.

the Topography
bronze-bonded of the diamond abrasive
bronze-bonded grinding
diamond abrasivewheel
grindingafter pulsed
wheel fiber
after pulsed
laser dressing. (a) Laser power density: 1.68 × 10 W/cm ; (b) Laser power density: 2.52 × 10 W/cm2;
fiber laser dressing. (a) Laser 8
power 2
density: 1.68 × 10 8
8 W/cm2 ; (b) Laser power density:
(c) Laser power density:
2.52 ×3.36 × 108 2W/cm
108 W/cm 2. power density: 3.36 × 108 W/cm2 .
; (c) Laser

In the process of increasing the power density of the pulsed fiber laser from
1.68 × 108 W/cm2 to 3.36 × 108 W/cm2 , the removal rate of the bronze material gradually
increased. When the laser power density was 1.68 × 108 W/cm2 , the bronze material could
be removed; thus there was a suitable chip holding space between the diamond abrasive
grains, and the ideal abrasive grain height could be obtained, and the sharpening of the
bronze-bonded diamond abrasive grinding wheel could be realized. When the power
density of the pulsed fiber laser was 2.52 × 108 W/cm2 , the diamond abrasive tip was
finely broken with appropriate shape accuracy, which could achieve the micro-shaping
of the diamond abrasive grains and achieve the purpose of combining the truing and
sharpening of the diamond abrasive grinding tools. However, when the power density of
the pulsed fiber laser continued to increase to 3.36 × 108 W/cm2 , the diamond abrasive
grains were greatly deformed, the surface was graphitized, and some depressions appeared,
which needs to be avoided as much as possible to obtain an ideal dressing effect. There-
fore, for laser truing and sharpening diamond abrasive grinding tools, ideal laser process
parameters should be selected. Among them, a pulsed fiber laser with a power density
Appl. Sci. 2022, 12, 4683 19 of 21

of 2.52 × 108 W/cm2 ∼3.36 × 108 W/cm2 is the most suitable for dressing the diamond
abrasive grinding tools. It can not only properly remove the bronze bond materials, but
also enable truing of the diamond abrasive grains in a small amount, and achieve truing
and sharpening of the diamond abrasive grinding tools at the same time.

5. Conclusions
(1) From the perspective of the truing and sharpening of diamond abrasive grinding
tools, traditional processing methods, such as the diamond pen dressing method,
grinding method, and rolling method, and new dressing methods, such as the EDM
dressing method and laser dressing method, were described in detail. In comparison,
it was pointed out that the laser dressing of diamond abrasive grinding tools was a
green processing method with high efficiency and no environmental pollution.
(2) Considering the superposition accumulation effect of the serial energy QC and cou-
pling of the Fourier heat transfer model, the energy accumulation heat transfer model
for laser dressing was established, and numerical simulation of pulsed fiber laser
dressing of the bronze-bonded diamond abrasive grinding wheel was carried out. The
temperature evolution law of the bronze bond and diamond abrasive grains dressed
by pulsed fiber laser was obtained by using the numerical analysis of the model.
The numerical analysis showed that, when the laser power density was greater than
1.68 × 108 W/cm2 , the bronze-bonded diamond abrasive grinding wheel could be
sharpened. When the laser power density was greater than 2.52 × 108 W/cm2 , the
truing effect of the diamond abrasive grinding tools was achieved.
(3) An experiment on the laser dressing of a bronze-bonded diamond abrasive grinding
wheel was carried out. The surface topography of the bronze-bonded diamond
abrasive grinding wheel was photographed by a three-dimensional ultra-depth-
of-field microscope. The results showed that, when the laser power density was
2.52 × 108 W/cm2 ∼3.36 × 108 W/cm2 , it could not only properly remove the bronze
bond, but also better sharpen the diamond abrasive grains. It was confirmed that the
laser dressing method could achieve the combination of truing and sharpening of the
diamond abrasive grinding tools. The experiment not only demonstrated the correct-
ness and feasibility of the theoretical model but also provided process optimization
for research into the pulsed laser dressing of diamond abrasive grinding tools.

Author Contributions: Conceptualization, S.C. and Y.T.; methodology, S.C.; software, S.C. and W.L.;
validation, S.C. and W.L.; formal analysis, W.L.; investigation, W.L.; resources, J.S.; data curation,
K.D.; writing—original draft preparation, W.L.; writing—review and editing, W.L.; visualization,
S.C.; supervision, Y.T.; project administration, Y.T.; funding acquisition, S.C. All authors have read
and agreed to the published version of the manuscript.
Funding: This research was funded by the National Natural Science Foundation for Young Sci-
entists of China (Grant No. 51705141); the Research Foundation of Education Bureau of Hunan
Province, China (Grant No. 21B0523); the China Postdoctoral Science Foundation (No. 2019T120650,
2018M632835); and the Excellent Young and Middle-aged Scientific and Technological Innovation
Team of Colleges and Universities in Hubei Province (Grant No. T2020042).
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Not applicable.
Conflicts of Interest: The authors declare no conflict of interest.
Appl. Sci. 2022, 12, 4683 20 of 21

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