New profiling approach with geometrically defined cutting edges for sintered metal bonded CBN grinding layers

Abstract Sintered metal bonded CBN grinding wheels have a high potential for profile grinding. Until now, their wide industrial application has been limited by time-consuming and expensive dressing technologies. This challenge can be solved by using a new profiling approach with geometrically defined cutting edges. The structure of sintered metal bonded CBN grinding layers is similar to the one of metal-matrix-composites (MMC). Various researchers have already proven the machinability of MMC materials. The aim of this work is correlate the machinability of sintered bronze bonded CBN with the mechanical properties of the grinding layer. Therefore, the wear of the cutting inserts and the resulting process forces are correlated with the mechanical properties of the sintered metal bond. A form turning process is designed in consideration of the tool wear and workpiece quality in order to apply the metal bonded grinding wheel to gear grinding. The sharpening process with bonded sharpening tools is adapted for the stated purpose in order to present a complete dressing method for sintered metal bonded CBN grinding wheels.