Finish machining of mirror-like diamond surfaces using a composite electroplating in-process sharpening method

Finishing mirror-like surfaces on chemically vapor-deposited diamond film using an in-process composite electroplating of diamond grains onto the tool surface, the tool can maintain its sharpness in a grinding process. The effect of diamond grit size of the tool on the grinding characteristics of diamond film is investigated. To promote optimum grinding efficiency, a high variation rate in the surface roughness of diamond film and a small growth rate in the coating thickness are desired. A distribution model of the diamond grits in the coating layer is deduced, and a composite electroplating in-process sharpening grinding mechanism is developed using a body-centered tetragonal structure. A two-stage composite electroplating in-process sharpening grinding procedure is used to grind the diamond film. A grit size of 25 µm is selected to conduct the composite electroplating in-process sharpening grinding for 30 min at an initial surface roughness of 1.1 µm. Then, the operating conditions are switched to a gri...