Technology Produces New Superabrasive Tools
A research team from the Indian Institute of Technology Madras has developed a new technology that can reportedly produce new-generation superabrasive tools for advanced grinding applications.
Benefits of these tools include meeting high productivity, energy efficient material removal requirements and enhanced tool life. The research team was led by Dr. Amitava Ghosh, a professor from the Department of Mechanical Engineering at IIT Madras.
About the Technology
According to the Government of India Department of Science and Technology, grinding industries have voiced the need for developing advanced superabrasive cBN/diamond tools that meet high productivity and energy-efficient material removal requirements, with customization based on local needs.
Ghosh and his team have reportedly used advanced chemical bonding technology with an application-specific novel formulation of filler material and controlled spacing of grits on the tools by an indigenously developed semi-automatic grit-printing device.
The superabrasive tools are produced using active brazing technology, with attributes of high crystal exposure above bond level. The Department of Science and Technology reports that the joint strength and wear-resistant characteristics of bond are higher compared to commercial counterparts, with the tools withstanding more grinding force, offering higher tool life and executing load-free grinding of advanced materials with an extremely high material removal rate.
These versatile geometry tools can then reportedly be tailor-made to suit a variety of industries, such as aerospace, automobile, mining and dental surgery.
For the coating application, the team recommends utilizing application-specific-advanced coatings. The novel formulation reportedly offers an excellent blend of strength, wear resistance and wetting characteristics.
Then, the grit-planting, or placing of grits in pre-defined coordinate position on grinding wheel's working surface, setup allows a manufacturer to print grit in a customized pattern to suit the requirement of an application. The recommended coating then enhances the durability of the bond, adding life to the developed tools.
The research was one of seven projects presented by IIT Madras at the ITTs R&D Fair, hosted at IIT Delhi on Oct. 14-15. The study has also been published in the Journal of Manufacturing Processes.
According to the Institute, projects presented at the fair are significant technological innovations that are intended to make a social impact on the community at large. Submitted under the theme of manufacturing, the new-gen single/multipoint superabrasive tools join cBN and diamonds on steel substrates through advanced active brazing technology.
“The research team developed indigenous advanced formulations of brazing fillers and a semi-automatic grit printing set-up which are essential for producing such next-generation tools,” wrote IIT Madras. “These tools are claimed to be remarkably superior to commercial counterparts in terms of high tool life and the capability of grinding materials with an extremely high material removal rate without wheel-loading.”
The tool research was supported by the Core Research Grant (CRG) of the Science and Engineering Research Board (SERB), a statutory body of the Department of Science and Technology (DST). Additionally, it fits the requirements of Make-in-India National Mission under lab validation and is reportedly near-ready to be taken up by a start-up or any industry for a full-scale launch.
The prototypes of various tools have been developed in a laboratory and are reportedly being experimentally test-simulated under industrial conditions. Patents for the technology have been filed and are under review for approval.