Fabrication of Vitrified Bond Diamond Grinding Wheel via LCD Photopolymerization

Abstract

In this paper, a liquid crystal display (LCD) photopolymerization method is proposed, and a vitrified bond diamond grinding wheel is successfully prepared. A high-performance vitrified bond was obtained by melting SiO2-B2O3-Al2O3-Na2O ceramic raw materials and used for grinding wheel preparation. LCD photopolymerization technology is characterized by high precision in shaping, fast processing speed, and superior quality, making it a promising technology for fabricating vitrified bond diamond grinding wheels. The preparation of vitrified bond slurry with high solid content and low viscosity was extensively investigated to meet the fabrication requirements. The effects of dispersant, the particle size of the vitrified bond, and solid content on the viscosity of the slurry were systematically analyzed. The vitrified bond slurry with solid content up to 65 wt.% (approximately 45.5 vol.%) was successfully prepared and met the requirements for printing. Furthermore, we explored the optimal formulation of the grinding wheel, debinding and sintering conditions, sintering temperature, grit-to-bond ratio, and the evaluation of the grinding performance of the wheel on hard and brittle materials, such as silicon carbide ceramic. Vitrified bond and abrasive slurry systems with a solid content of 65 wt.% (approximately 42.8 vol.%) were prepared. The results show that the vitrified bond diamond grinding wheel exhibits optimal comprehensive performance, with a sintering temperature of 680 °C and a grit-to-bond ratio of 4:6. The minimum surface roughness of the workpiece after grinding was 1.767 μm, the material removal rate was 5.08 mg/s, the grinding ratio was 9.78, and the friction coefficient was stabilized at about 0.5 during grinding. This paper guides the manufacturing of vitrified bond diamond grinding wheels via LCD photopolymerization.