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Grinding characteristics of CVD diamond grits in single grit grinding of SiC ceramics

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Abstract

Single crystalline diamond (SCD) grits are usually made by a high-pressure and high-temperature (HPHT) method and exhibit cuboctahedral shapes and smooth surfaces. In this paper, we synthesized new kinds of SCD grits and nanocrystalline diamond (NCD) grits by a chemical vapor deposition (CVD) method and explored their grinding performance by single grit grinding of SiC ceramics. Grinding by HPHT grits was also conducted for comparison. The CVD-SCD grits exhibit cuboctahedral shapes, but surfaces are covered by protruded twin crystals of several microns, while the NCD grits are spherical agglomerations of nano-grains. We demonstrated that these morphological features have profound influences on material removal behavior. Results show that the wear of NCD grits is dominated by wear flat and intergranular cracks. The worn NCD grits can exert intense rubbing and ploughing effects on the workpiece. In contrast, the wear of CVD-SCD grits is dominated by fracture of the protruded twin crystals. It is proved that the twins on the grit surface are effective cutting edges to remove the material in a micro scale and thus lead to the formation of fine grinding striations and smaller cracking pits, but this process has little influence on specific grinding energy. Besides, grits with rough twins, especially on the flank face, tend to exhibit lower grinding force ratios and thus better sharpness. Moreover, for grits with smooth rake faces, there exists an explicit critical undeformed chip thickness value around 0.4–0.6 μm, above which the material removal mechanism changes from ductile to brittle rapidly. However, for grits with rough twins on rake faces, this transition process becomes vague.

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Availability of data and materials

The datasets used in our study are available from the corresponding author on reasonable request.

Code availability

Not applicable. No code are included in this manuscript.

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Funding

This research is supported by the National Natural Science Foundation of China (No. 51775339).

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Authors and Affiliations

  1. School of Mechanical Engineering, Shanghai Jiao Tong University, Dongchuan Road 800, Minhang District, Shanghai, 200240, China

    Xiaotian Shen, Xin Song, Xinchang Wang & Fanghong Sun

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  1. Xiaotian Shen
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  2. Xin Song
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  3. Xinchang Wang
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  4. Fanghong Sun
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Contributions

X. S. was the main author that wrote this manuscript, designed the experiment and finished the analysis. X. S. provided the fabrication parameters and details of CVD diamond grits, and analyzed data. X. W. helped to conduct the single grit grinding tests. F. S. provided the funding and revised the manuscript.

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Correspondence to Fanghong Sun.

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Shen, X., Song, X., Wang, X. et al. Grinding characteristics of CVD diamond grits in single grit grinding of SiC ceramics. Int J Adv Manuf Technol 114, 2783–2797 (2021). https://doi.org/10.1007/s00170-021-07026-1

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