Scientists at IIT Madras are developing a technology for manufacturing new generation superabrasive tools

NEW DELHI: A domestic technology developed at IIT Madras can now manufacture new-generation superabrasive tools for advanced grinding applications to meet demands for high productivity and energy-efficient material removal, the Ministry of Science and Technology said in a news release on Thursday.

“A research team led by Amitava Ghosh at IIT Madras 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-automated grain pressure device,” the ministry added.

The team recommended application-specific advanced coatings to develop new generation superabrasive tools. 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).

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.

“These superabrasive tools can be made using active brazing technology with remarkably striking properties of high crystal exposure above bond level. The joint strength and wear resistant bond properties of these tools are superior to their commercial counterparts. These tools can withstand higher grinding force, offer significantly longer tool life and perform load-free grinding of advanced materials with an extremely high stock removal rate,” the ministry said.

The tool is 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). It offers a competitive cost with a tool of the highest quality that is also tailored to the needs of industries such as aerospace, automotive, mining and dental.

“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 way of manufacturing superabrasive tools has been published in the Journal of Manufacturing Process and the patents filed are being reviewed for approval,” the ministry added.

This technology meets Make-in-India National Mission requirements and is lab validated. It’s almost ready to be adopted by a startup or any other industry for a full commercial launch.

The application-specific indigenous formulation of active fillers to bond superabrasives to metal substrates through state-of-the-art active brazing technology is a key first that can be exploited for the large-scale manufacturing industry.

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