Synthetic Diamond Dressing Tools

Tooling containing the latest dressing materials to answer today's precision grinding problems:

  • Monodress (Monocrystalline Synthetic Diamond)

  • CVD (Synthetic diamond by Chemical Vapour Deposition)

  • TSP (Thermally Stable Polycrystalline Diamond)

 

Introduction

Traditionally, dressing and forming of grinding wheels designed to achieve close tolerances with high surface finish has been achieved using a variety of polished, natural diamonds or cluster tools. These tools are, however, subject to the inherent variation of any natural product and require considerable input from the operator to achieve consistently good results. To exploit the advantages of modern CNC machinery to the full, Hamilton Lichfield has developed a range of synthetic dressing tools which, in one application, have been proven to hold 2.0 micron tolerances with 6 micro inch (Ra) surface finish, over long production runs.

 

Advantages of Synthetic Diamond Tooling

Repeatability -Each successive tool is the same as the first one and in use the results obtained can be guaranteed time and again.

Constant Cross-sectional Area - Tools wear evenly over the length of the diamond, typically 5mm, therefore automatic wheel dressing and compensation can be employed.

Availability - Synthetic tooling is available in a range of sizes so that the contact area of the diamond can be matched exactly to the needs of your particular application.

Cost - Synthetic diamond tooling is often cheaper than the conventional tooling it replaces, particularly macle chisel tools. However, the major cost savings can be found when analysing the cost per part, machine down times and scrap rates.

Limitations

  • Generally not suitable for very hard wheels, such as coarse green grit wheels

  • Machine operators required to learn new dressing techniques

 

Applications

The choice of the correct dressing medium will depend upon your exact application and our technical staff are always available to offer advice and if necessary develop specific tools to suit your individual requirements. However, the following notes broadly describe the most cost effective areas.

Monodress
An excellent material without the inclusions and flaws found in all but the best natural diamond. Suitable for a wide range of polished tools but also used singly or in multiples within blade tools for form and straight pass grinding.
CVD
We have found this material to be particularly suited to the manufacture of lapped chisel tools for the production of consistently accurate forms. Although not quite as hard as natural diamond it is very durable and because of a progressive breakdown is capable of holding tight tolerances for long periods between relaps. CVD 'logs' also provide a cheaper substitute for Monodress cluster tools.
TSP
Although TSP has been available for longer than the other material new applications are still being found for it. Hamilton Lichfield has had success with TSP as a very cost effective 'single point' dressing tool where the cross-sectional area of the TSP is matched to the grinding wheel producing results equal to the sharpest octahedron diamonds. TSP is also used in blade format for form and straight pass grinding. It is the cheapest of the options available

Dressing Technique

A different technique is required when utilising synthetic diamond tooling. Hamilton Lichfield will gladly assist in establishing the correct procedures but the following are the main principles:

  • Choose the correct area of contact

  • Orientate the diamonds correctly

  • Use more frequent dressing cycles

  • Use light infeeds

For more information regarding Synthetic Diamond Tooling.