Simulation and manufacturing of metal brazed CBN grinding tools

Grinding processes are essential for achieving high-precision manufacturing in industries such as aerospace, automotive, and medical devices. However, conventional cubic boron nitride (CBN) grinding tools often face limitations, including excessive forces, high temperatures, and restricted tool life, which hinder efficiency and precision. This research primarily focuses on brazing as a transformative technique for manufacturing advanced grinding tools, while also exploring laser ablation as a complementary method to further enhance tool performance.The brazing process utilized Ti-bronze as a bonding material to attach CBN abrasive grits to a steel substrate. Key challenges such as material compatibility, uniform grit distribution, and oxidation during furnace operations were systematically addressed through process optimization. A controlled atmosphere was implemented to ensure oxidation-free brazing and uniform bonding. Experimental evaluations demonstrated that brazed CBN tools achieved significant reductions in grinding forces (19–21%) and workpiece temperatures (25–27%) compared to conventional non-patterned CBN tools. While the surface roughness values for brazed tools were slightly higher, these remained within acceptable industrial tolerances, making brazing a cost-effective and flexible alternative for applications with moderate surface finish requirements.To assess the structural integrity of brazed tools, a finite element analysis (FEA) framework was developed. The simulations validated the bonding strength of the brazed layer and revealed its thermal dissipation capabilities under grinding stresses. This framework provided insights into the thermal-mechanical stability of brazed tools, further substantiating their feasibility for high-performance grinding applications. Moreover, FEA highlighted the critical influence of furnace parameters, material composition, and grit distribution on overall tool performance, guiding further process refinements.To complement brazing developments, laser ablation was investigated as a supplementary technique for enhancing grinding performance. Laser-structured patterns on CBN tools improved chip evacuation and cooling by facilitating fluid penetration. Experimental results showed that laser-patterned tools reduced grinding forces by 22–25% and workpiece temperatures by 28–30%, surpassing the performance of conventional tools. However, surface roughness for laser-patterned tools was slightly higher than for traditional tools, albeit within acceptable tolerances.A digital twin framework was integrated with model-based simulations to further optimize brazing and laser ablation processes. This approach allowed for iterative parameter adjustments to predict and refine grinding tool performance metrics, such as forces, temperatures, and surface finishes, prior to fabrication. The digital twin not only improved development efficiency but also minimized material waste during the manufacturing process.The findings of this research highlight brazing as a versatile and cost-effective manufacturing method for high-precision grinding tools, offering significant advantages in terms of process flexibility and performance improvements. While laser ablation provides notable performance enhancements, brazing emerges as the more economically viable solution, particularly for applications with less stringent surface finish requirements. The combination of experimental validation, FEA, and digital twin modeling ensures a comprehensive understanding of the underlying mechanisms driving the performance of brazed tools.This study represents a substantial advancement in the field of grinding technology, addressing critical challenges in tool design and manufacturing. Future research will focus on refining the brazing process further by exploring alternative bonding materials, optimizing conditions, and expanding FEA models to incorporate complex interactions. Together, these developments aim to establish sustainable, efficient, and high-performance grinding processes for industries requiring high-precision machining.