1. Diamond grinding wheels are pre-mixed with a filler material, which can be a salt, glass beads, or magnetic particles. After bonding, the filler particles, typically 5 microns thick, are bonded by a metal binder. These filler particles are then removed using methods such as dissolution, lifting, or magnetic field methods. In this method, the size of the filler particles is approximately the same as the size of the diamond abrasive particles, and the amount of filler used allows the diamond grinding wheel to reach the standard concentration on the mold working surface. The disadvantage of these methods is that the removal of the filler is very complex and requires a specialized set of procedures.
2. Another simpler method for removing the filler uses spherical filler particles with a smooth surface. The main deposition of the metal binder is to a thickness of 5% of the height of the diamond abrasive particles (initial deposition), and then the filler is brushed away. Finally, the metal binder is continuously deposited to the standard thickness. This method utilizes the effect that the metal binder has different control capabilities on particles with different surface roughness and shapes. Its disadvantage is that the size of the filler particles is similar to the size of the diamond abrasive particles, so they are on the same plane after bonding. When removing the filler mechanically, some diamond abrasive particles may be removed along with it, especially those with shapes close to isometric and those with smooth surfaces.
3. As an improvement to the above methods, the filler particle size is selected to be 1.5-5.0 times the size of the diamond abrasive particles. When the metal binder is initially electrodeposited, the diamond grinding wheel is bonded by a metal binder layer approximately 5% of its height, while the filler particles are bonded by a metal binder layer approximately 4-13% of their height. This thickness of the metal binder layer cannot control all shapes and surface roughness of the filler particles, so the filler can be easily removed from the grinding wheel surface by gently brushing, using an oilstone, or a cutting tool.
The above are the diamond grinding wheel processing methods we've shared, and we hope they will be helpful to you. Each method has its unique advantages and characteristics, and you can also modify them based on your own experience to create a method that perfectly suits your product.