Indian scientists develop novel technology to manufacture new generation super abrasive tools

A team of scientists at the Indian Institute of Technology (IIT) Madras has developed a new indigenous technology to produce new generation superabrasive tools.

The newly developed technology can manufacture multi-point/single-layer super grinding tools for advanced grinding applications to meet the demands of high productivity and energy-efficient stock removal.

The tools made with the new technology also have a longer service life.

The grinding industry has advocated the development of advanced superabrasive cBN/diamond tools that meet the high productivity and energy efficient material removal requirements and customization to local needs.

“A research team led by Dr. Amitava Ghosh at IIT Madras has used advanced chemical bonding technology with an application-specific novel formulation of filler material and controlled spacing of grains on the tools by a proprietary semi-automatic grain pressure device,” the Ministry of Science and Technology said in a statement on Thursday ( November 3rd).

The team is recommending application-specific advanced coatings to develop such new-generation superabrasive tools, the ministry said.

The novel formulation offers an excellent blend of strength, wear resistance and wetting properties (ability to spread well in the liquid state with low contact angle on solid superabrasives during brazing), she added.

The facility for depositing grains (arranging/placing grains in predefined coordinate positions on the working surface of the grinding wheel) allows a manufacturer to print grains in a custom pattern to meet the needs of an application.

The recommended coating increases the durability of the binding and thus extends the life of the developed tools.

In short, these superabrasive tools can be made using active brazing technology with remarkably striking properties of high crystal exposure above bond level, the ministry said.

The joint strength and wear resistant bond properties of these tools are superior to their commercial counterparts.

These tools can withstand higher grinding forces, offer significantly longer tool life and perform load-free grinding of advanced materials with an extremely high stock removal rate.

Supported by the Core Research Grant (CRG) from the Science and Engineering Research Board (SERB), a statutory body of the Department of Science and Technology (DST), this native tool offers a competitive cost with a top-quality tool that it also is tailored to the needs of industries such as aerospace, automotive, mining and dental surgery, the ministry said.

The technology can produce new generation tools with versatile geometries. The prototypes of various tools were developed in the laboratory and are experimentally test-simulated under industrial conditions.

This innovative way of presenting the novel method of manufacturing superabrasive tools was recently published in the Journal of Manufacturing Process, and the patents filed are being reviewed for approval, the ministry said.

This technology, which meets Make-in-India National Mission requirements, is in laboratory validation and near-ready to be adopted by a start-up or other industry for full roll-out, according to the ministry.

The application-specific indigenous formulation of active fillers to bond superabrasives to metal substrates through cutting-edge active brazing technology is a key first that can be exploited for large-scale manufacturing industries, the ministry said.

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