Grinding performance evaluation of a novel 3D-printed double-layer diamond grinding head in cemented carbide grinding

In order to address the significant waste of diamonds associated with conventional diamond grinding heads when machining cemented carbide, this paper proposed a novel double-layer diamond grinding head specifically designed for grooving cemented carbide. This innovative design features diamond particles exclusively on the outer wall and is fabricated using dual-nozzle FDM 3D printing technology. New grinding heads were developed with different diamond concentrations, particle sizes, and cobalt (Co) content. Subsequently, grinding experiments on cemented carbide were carried out. A comparative analysis was performed across a series of new grinding heads in terms of mechanical properties, removal rate, abrasive ratio, workpiece surface morphology, and wear characteristics of grinding head. This investigation aimed to explore how the design parameters of the grinding head components influences its grinding performance. The test results show that the diamond particle size has the greatest effect on both mechanical properties and grinding performance of the grinding head, followed by the Co content and diamond concentration. Increasing the diamond concentration improves the mechanical properties of the grinding head and provide more contact points during grinding, making the grinding surface smoother and increasing the wear resistance of the grinding head. Conversely, an increase in diamond mesh (decrease in diamond particle size) significantly diminishes both mechanical properties and wear resistance as well as grinding efficiency, however, it greatly reduces surface roughness post-grinding. In addition, the addition of Co reduces the relative density while increasing the hardness and grinding performance of the grinding head, and strengthens the holding force of the matrix. However, excessive holding force may hinder exposure of abrasive particles or even cause slippage during use. © 2024 Elsevier Ltd