Tool Steel Selection for Precision Electrode Slitting Blades
Precision electrode slitting requires powder metallurgy tool steels with high vanadium carbide volume to eliminate micro-chipping and maintain burr limits below 10 µm.
Resin Bonded Diamond Wheels
Meaning
Grinding tools consisting of synthetic diamond abrasive grains held together by a phenolic or polyimide resin matrix. These wheels provide a resilient and cool-cutting action suitable for sharpening extremely hard materials. Precision finishing of tungsten carbide battery dies relies on resin bonded diamond wheels to achieve the required edge sharpness without causing thermal damage.
Composite Structure
The manufacturing process involves mixing diamond powder with resin and fillers before pressing and curing the mixture onto a steel or aluminum core. Because resin bonded diamond wheels have a degree of elasticity, they can conform slightly to the tool surface to produce a superior finish compared to more rigid bonding systems. The choice of resin affects the heat resistance and the hardness of the wheel, allowing it to be tailored for specific grades of carbide or ceramic.
High-performance versions use polyimide resins to withstand the temperatures generated during heavy stock removal. Durability varies with bond selection.
Grinding Performance
The soft matrix allows new, sharp diamond edges to be exposed as the wheel wears, maintaining a consistent cutting rate. While metal bonded wheels are more durable, resin bonded diamond wheels are preferred for finishing because they minimize the risk of surface cracking in the workpiece. Heat generation is low.
Maintenance Application
Tool rooms use these wheels to restore the micro-geometry of electrode punches that have become dull during production. Because the finish quality determines the burr height on the electrode foil, resin bonded diamond wheels are the standard choice for final polishing operations. They ensure a clean cut.