Tula State University, Polytechnic Institute, Tula, Russia:

A. V. Evseev, Doctoral Student, e-mail: ews1972@mail.ru
M. S. Paramonova, Postgraduate Student
V. V. Preis, Professor
A. V. Lobanov, Associate Professor

This paper looks at one of the techniques for producing abrasive diamond tools, which involves two main processes: 1 – preparation of a diamond (usually synthetic) powder mixture with metal bonds which is made of electrolytic copper and tin and manganese-nickel powders; 2 – installation of this integrated sinter on a metal disk or another metal tool by baking or pressing. The quality and performance of the resultant tool is to a great extent pre-determined by the quality characteristics of the diamond and metal mixture, which depend on the processes involved in the mixture production and installation. The specific powder metallurgy process involved in the production of abrasive diamond tools significantly limits the applicability of the conventional approach to assessing the mixture quality by the key component and makes it difficult to analyse the performance of the mixture and the final tool. All the existing processes for producing mixtures (including metal bonds) are of probabilistic nature governing to a certain degree the performance of final mixtures and what is made with them – in this particular case, abrasive diamond tools. And it is not always possible to predict their performance. That’s why the authors proposed a new process for preparing the diamond and metal mixture, which uses turbo-mixers and the previously proposed technique of deterministic formation of homogenous mixture of diamond powder and copper-tin bonds. A method was developed to produce abrasive diamond tools with a pre-defined distribution of diamond grains across the cutting layer. Natural experiments, which were conducted in a special mixer, support the results of modelling of the above processes. The authors also developed a tool testing technique which helped establish a correlation dependence between the distribution of components in the cutting layer and the tool’s performance. The latter is analysed based on the specific consumption of diamond powder within a given convergence criterion.

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