Skip to main content
SpringerLink
Log in

Experimental study of metal ceramic (WC-Co) micro-tool fabrication by controlled inclined grinding (CIG)

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

As a kind of metal ceramic material, cemented carbide (WC-Co) has attracted attentions of many scholars for its excellent material property. In this paper, a new method named controlled inclined grinding (CIG) is proposed to fabricate a micro-substrate of cemented carbide. The machining mechanism during CIG was investigated; a lot of micro-substrates, whose diameter is from 8 to 120 μm, had been successfully fabricated; and the critical parameters for obtaining the suitable machining result are given. Two ultra-small micro-tools, with a diameter of 8 μm and 20 μm, respectively, and an aspect ratio (for both) of bigger than 50, had been fabricated by the CIG method. The relationship between tool contour and inclined angle (θ) was revealed, and the optimal inclined angle was found to be 0.5°. Differences when grinding at different wheel positions were studied and compared, and an optimal grinding position was found. A contrast experiment was designed and carried out by using the CIG method and traditional grinding method, and machined workpiece surface was observed by a profilometer and a scanning electron microscope (SEM); it is found that the machined surface of the CIG method was comparatively gentle and even, while the machined surface of the traditional method was violent and uneven. A surface roughness model for the CIG method was built, the corresponding expression was derived, and the surface roughness model was finally validated experimentally. The CIG method proposed in this study is not only a simple device but also cheap and efficient, and it is anticipated to be an optional method to fabricate micro-tool.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Masuzawa T (2000) State of the art of micromachining. CIRP Ann Manuf Technol 49(2):473–488

    Article  Google Scholar 

  2. Ohmori H, Katahira K, Naruse UTY, Nakao A, Mizutani M (2007) Microscopic grinding effects on fabrication of ultra-fine micro tools. CIRP Ann Manuf Technol 56(1):569–572

    Article  Google Scholar 

  3. Aurich JC, Carrella M, Walk M (2015) Micro grinding with ultra small micro pencil grinding tools using an integrated machine tool. CIRP Ann Manuf Technol 64(1):325–328

    Article  Google Scholar 

  4. Onikura H, Ohnishi O, Take Y, Kobayashi A (2000) Fabrication of micro carbide tools by ultrasonic vibration grinding. CIRP Ann Manuf Technol 49(1):257–260

    Article  Google Scholar 

  5. Aurich JC, Engmann J, Schueler GM, Haberland R (2009) Micro grinding tool for manufacture of complex structures in brittle materials. CIRP Ann Manuf Technol 58(1):311–314

    Article  Google Scholar 

  6. Zhang ZY, Cui JF, Wang B, Wang ZG, Kang RK, Guo DM (2017) A novel approach of mechanical chemical grinding. J Alloy Compd 726:514–524

    Article  Google Scholar 

  7. Zhang ZY, Du YF, Wang B, Wang ZG, Kang RK, Guo DM (2017) Nanoscale wear layers on silicon wafers induced by mechanical chemical grinding. Tribol Lett 65:132

    Article  Google Scholar 

  8. Zhang ZY, Huang SL, Wang SC, Wang B, Bai Q, Zhang B, Kang RK, Guo DM (2017) A novel approach of high-performance grinding using developed diamond wheels. Int J Adv Manuf Technol 91(9–12):3315–3326

    Article  Google Scholar 

  9. Zhang ZY, Wang B, Kang RK, Zhang B, Guo DM (2015) Changes in surface layer of silicon wafers from diamond scratching. CIRP Ann Manuf Technol 64(1):349–352

    Article  Google Scholar 

  10. Zhang ZY, Guo DM, Wang B, Kang RK, Zhang B (2015) A novel approach of high speed scratching on silicon wafers at nanoscale depths of cut. Sci Rep 5:16395

    Article  Google Scholar 

  11. Cheng X, Wang ZG, Nakamoto K, Yamazaki K (2011) A study on the micro tooling for micro/nano milling. Int J Adv Manuf Technol 53(5–8):523–533

    Article  Google Scholar 

  12. Chen ST, Tsai MY, Lai YC, Liu CC (2009) Development of a micro diamond grinding tool by compound process. J Mater Process Technol 209(10):4698–4703

    Article  Google Scholar 

  13. Perveen A, San WY, Rahman M (2012) Fabrication of different geometry cutting tools and their effect on the vertical micro-grinding of bk7 glass. Int J Adv Manuf Technol 61(1–4):101–115

    Article  Google Scholar 

  14. Butler-Smith PB, Axinte D, Daine M (2012) Solid diamond micro-grinding tools: from innovative design and fabrication to preliminary performance evaluation in Ti-6Al-4V. Int J Mach Tools Manuf 59:55–64

    Article  Google Scholar 

  15. Cabrera M, Dahmania R, Layounia Y, Semet V (2016) Micro EDM milling with electrochemical fabrication of ultra-thin microtools and mapping of electrical microdischarges. Proceed CIRP 42:650–655

    Article  Google Scholar 

  16. Ali MY, Ong AS (2006) Fabricating micromilling tool using wire electrodischarge grinding and focused ion beam sputtering. Int J Adv Manuf Technol 31(5–6):501–508

    Article  Google Scholar 

  17. Chern GL, Wu YJE, Cheng JC, Yao JC (2007) Study on burr formation in micro-machining using micro-tools fabricated by micro-edm. Precis Eng 31(2):122–129

    Article  Google Scholar 

  18. Hourmand M, Sarhan AAD, Noordin MY (2017) Development of new fabrication and measurement techniques of micro-electrodes with high aspect ratio for micro edm using typical edm machine. Measurement 97:64–78

    Article  Google Scholar 

  19. Yin Q, Wang X, Wang P, Qian Z, Zhou L, Zhang Y (2016) Fabrication of micro rod electrode by electrical discharge grinding using two block electrodes. J Mater Process Technol 234:143–149

    Article  Google Scholar 

  20. Xu K, Zeng YB, Li P, Zhu D (2017) Vibration assisted wire electrochemical micro machining of array micro tools. Precis Eng 17:487–497

    Article  Google Scholar 

  21. Wang YF, Zeng YB, Qu NS, Zhu D (2016) Electrochemical micromachining of small tapered microstructures with sub-micro spherical tool. Int J Adv Manuf Technol 84(5–8):851–859

    Google Scholar 

  22. Wang B, Zhang ZY, Chang KK, Cui JF, Rosenkranz A, Yu JH, Lin CT, Chen GX, Zang KT, Luo J, Jiang N, Guo DM (2018) New deformation-induced nanostructure in silicon. Nano Lett 18(7):4611–4617

    Article  Google Scholar 

  23. Sun Y, Gong YD (2018) Experimental study on fabricating spirals microelectrode and micro-cutting tools by low speed wire electrical discharge turning. J Mater Process Technol 258:271–285

    Article  Google Scholar 

  24. Liu XF, Zhang JH, Hu XY, Wu DB (2019) Influence of tool material and geometry on micro-textured surface in radial ultrasonic vibration-assisted turning. Int J Mech Sci 152:545–557

    Article  Google Scholar 

  25. Ji W, Zou B, Zhang S, Xing H, Yun H, Wang Y (2018) Design and fabrication of gradient cermet composite cutting tool, and its cutting performance. J Alloy Compound 732:25–31

    Article  Google Scholar 

  26. Malkin S (1989) Grinding technology: theory and applications of machining with abrasives. SME

Download references

Funding

This paper work was supported by the National Natural Science Fund of China (No. 51575096 and No. 51375082) and by the Shenzhen Changxing Technology Co., Ltd., China.

Author information

Authors and Affiliations

  1. Advanced Manufacturing Institute, Northeastern University, P.O. Box 319, Shenyang, 110004, People’s Republic of China

    Chunchun Gao, Jun Cheng & Jun Wu

Authors
  1. Chunchun Gao
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jun Cheng
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jun Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jun Cheng.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Gao, C., Cheng, J. & Wu, J. Experimental study of metal ceramic (WC-Co) micro-tool fabrication by controlled inclined grinding (CIG). Int J Adv Manuf Technol 103, 2151–2167 (2019). https://doi.org/10.1007/s00170-019-03658-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-03658-6

Keywords

Search

Navigation