Present paper delineates a novel route adopted for successfully manufacturing single layer brazed patterned diamond wheels with enhanced attributes. A pneumatic pick-drop methodology is used for placing the grits in a uniform and patterned manner. Instead of commonly used Ni-Cr alloys, a novel formulation of μ-TiC inoculated composite Ag-Cu-Ti filler has been preferred, which helped in arresting crack formation at the root of grit brazement and simultaneously ensured high bond wear characteristics. Addition of μ-TiC particles substantially improved wear characteristics of basic Ag-Cu-Ti alloy but tend to impair its wetting ability on diamond surface with increase in its wt% in the composition. Therefore, its presence in the filler was restricted to only 2 wt% to keep such compromise within acceptable level. Wheels developed using active Ag-Cu fillers were further subjected to performance evaluation by grinding of WC-Co cermets. The operating parameters were changed in such a way that wheels experienced increasing order of grinding-aggressiveness. The degree of aggressiveness in the grit-work interaction has been defined by a unifying scalar quantity, termed as “aggressiveness number”. No trace of wheel loading was observed even in the most aggressive condition due to uniformly spaced grits. The failure counts of diamond grits are also related to this scalar. A detailed analysis is presented to address the suitability of μ-TiC reinforcement in the formulation of active Ag-Cu filler in the light of the grinding force and grit retention ability of the wheels.

本论文描绘了成功制造具有增强属性的单层钎焊图案金刚石砂轮所采用的新途径。气动拾取方法用于以均匀和图案化的方式放置磨粒。与常用的Ni-Cr合金不同，μ-TiC孕育复合Ag-Cu-Ti填料的新型配方已成为首选，这有助于阻止硬钎焊根部的裂纹形成，同时确保高结合磨损特性。添加μ-TiC颗粒显着改善了碱性Ag-Cu-Ti 的磨损特性合金，但随着其在组合物中的重量百分比的增加，往往会削弱其在金刚石表面上的润湿能力。因此，它在填料中的含量被限制在仅 2 重量％，以将这种折衷保持在可接受的水平内。使用活性Ag-Cu开发的车轮通过研磨 WC-Co 金属陶瓷对填料进一步进行性能评估。操作参数以这样一种方式改变，即砂轮经历磨削强度增加的顺序。砂砾工作交互中的攻击性程度由统一的标量定义，称为“攻击性数”。由于均匀分布的砂砾，即使在最具侵略性的条件下也没有观察到车轮负载的痕迹。金刚石磨粒的失效计数也与该标量有关。根据砂轮的磨削力和砂粒保持能力，详细分析了μ-TiC增强材料在活性Ag-Cu填料配方中的适用性。