Mechanical truing of V-shape diamond wheels for micro-structured surface grinding

An on-machine mechanical truing method with rotary green silicon carbide (GC) roller to precision shape and prepare V-shape diamond wheels for microstructured surface grinding was proposed. The effects of truing parameters on trued wheel profile accuracy were investigated. The experimental results showed that the feed direction of GC roller had a remarkable effect on truing accuracy. The V-tip radius of trued wheel was reduced with the increase of the GC roller speed or the decrease of the grinding wheel speed, truing depth per pass, feed rate, and the grain size of GC roller. The V-shape diamond wheel with less than 18-mu m V-tip radius and 0.6-mu m run-out (center zone of wheel) was produced by parameter optimization. Finally, the V-groove array was ground on silicon nitride mold material by the trued diamond wheels. Although the V-tip of diamond wheel can be trued to less than 18 mu m, the smallest corner radius, which was obtained in the first ground groove, was still bigger than 46 mu m due to the unavoidable wear of diamond wheel in the grinding process of hard mold material.