Modeling and prediction research on wear of electroplated diamond micro-grinding tool in soda lime glass grinding

Micro-wear in micro-grinding process is very important to research the micro-tools wear and the service life prediction of the micro-tools. The wear mechanism of electroplated diamond micro-grinding tool is analyzed in this paper. The geometric and mathematical modeling is established in allusion to the composite mechanism in micro-grinding zone and the main characteristics of the wear forms. The prediction model of micro-wear is established by considering the size effect and the minimum chip thickness. Experiments with different grinding parameters in micro-grinding soda lime glass are carried out to confirm the validity of the model. The influence of the worn micro-grinding tools are proposed by analyzing the diameter of grinding head, the ratio of wear and fracture grains, the surface roughness of the specimens, and different grinding parameters. The test results show that the grinding head diameter decreases rapidly and sharply first and then decreases slowly and steadily. The wear is more slowly with better surface quality. The wear rate and the ratio of wear and fracture grains increase with the increasing of grinding and feed speeds, and the ratio has a linear trend integrally. It provides the experimental reference and the theoretical basis for improving the grinding performance and extending the service life of micro-grinding tools.