Fabrication and Application of Gel Forming Ultrafine Diamond Abrasive Tools

To solve the problem of phase agglomeration and microstructure inconsistency in the conventional powder pressing method of ultrafine diamond abrasive tool, a fabrication method of ultrafine diamond abrasive tool based on gel forming was proposed. The gel experiments of polyvinyl alcohol (PVA) and phenolic resin (PF) were carried out, and the basic physicochemical properties of the gel were tested by SEM, IR and TGA. The mechanical properties of gel forming and hot pressing forming abrasive tools were Compared. The polishing experiments of the gel abrasive tool and the hot-pressing abrasive tool were carried out. The results showed that when the PF/PVA ratio was between 5:1 and 10:1, the porous network gel structure was formed. The IR and TGA analysis indicated that the molecular crosslinking of PF and PVA occurred after gel. Compared with hot pressing abrasive samples, the abrasive distributions of gel abrasive samples were more uniform. The supersmooth surface of the SiC flat mirror with surface roughness Ra below 3 nm was obtained by the gel abrasive tool, which was better than by hot pressing abrasive tool. The surface flatness value PV 0.213 μ m could be obtained by using the gel abrasive tool with low PVA content.