Feasibility study on sharpening metal-bond metal diamond grinding tool by microwave-induced electric discharge machining

Microwave-induced electric discharge machining (MV-EDM) is an emerging machining method that can be applied to fine machining of metal materials. A feasibility analysis of the application of MV-EDM to sharpen diamond grinding tools was conducted in this study. A multiphysical simulation model for sharpening using MV-EDM was established, and MV-EDM sharpening experiments and measurements were performed to verify the accuracy of the simulation model. It was found that MV-EDM can effectively improve the protrusion height hp and does not result in severe graphitization of diamond grains under appropriate conditions. Under the conditions of a microwave power of 1 kW and a gap scale d of 0.1 mm, the hp of the diamond grain increased to 91 μm with a complete diamond crystal shape and slight graphitization. In addition, it was discovered that the gap scale d and initial protrusion height h0 had a significant effect on the protrusion height hp and the graphitization of the diamond grains. After verification, the accuracy of the simulation model for calculating the protrusion height of diamond grains was controlled within a range of ±15 μm. The results of this study provide a theoretical basis for the industrial application of MV-EDM to sharpening.