In order to address the significant waste of diamonds associated with conventional diamond grinding heads when machining cemented carbide, this paper proposed a novel double-layer diamond grinding head specifically designed for grooving cemented carbide. This innovative design features diamond particles exclusively on the outer wall and is fabricated using dual-nozzle FDM 3D printing technology. New grinding heads were developed with different diamond concentrations, particle sizes, and cobalt (Co) content. Subsequently, grinding experiments on cemented carbide were carried out. A comparative analysis was performed across a series of new grinding heads in terms of mechanical properties, removal rate, abrasive ratio, workpiece surface morphology, and wear characteristics of grinding head. This investigation aimed to explore how the design parameters of the grinding head components influences its grinding performance. The test results show that the diamond particle size has the greatest effect on both mechanical properties and grinding performance of the grinding head, followed by the Co content and diamond concentration. Increasing the diamond concentration improves the mechanical properties of the grinding head and provide more contact points during grinding, making the grinding surface smoother and increasing the wear resistance of the grinding head. Conversely, an increase in diamond mesh (decrease in diamond particle size) significantly diminishes both mechanical properties and wear resistance as well as grinding efficiency, however, it greatly reduces surface roughness post-grinding. In addition, the addition of Co reduces the relative density while increasing the hardness and grinding performance of the grinding head, and strengthens the holding force of the matrix. However, excessive holding force may hinder exposure of abrasive particles or even cause slippage during use.

中文翻译：

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新型 3D 打印双层金刚石磨头在硬质合金磨削中的磨削性能评价


为了解决在加工硬质合金时与传统金刚石磨头相关的大量金刚石浪费问题，本文提出了一种专为硬质合金切槽而设计的新型双层金刚石磨头。这种创新设计仅在外壁上采用金刚石颗粒，并使用双喷嘴 FDM 3D 打印技术制造。开发了具有不同金刚石浓度、粒度和钴 （Co） 含量的新型磨头。随后，对硬质合金进行了磨削实验。对一系列新型磨头的机械性能、去除率、磨粒比、工件表面形态和磨头磨损特性进行了比较分析。本研究旨在探讨磨头组件的设计参数如何影响其磨削性能。试验结果表明，金刚石粒度对磨头的机械性能和磨削性能影响最大，其次是 Co 含量和金刚石浓度。增加金刚石浓度可以提高磨头的机械性能，并在磨削过程中提供更多的接触点，使磨削表面更光滑，增加磨头的耐磨性。相反，金刚石网孔的增加（金刚石粒度的减小）会显著降低机械性能和耐磨性以及磨削效率，但是，它会大大降低磨削后的表面粗糙度。此外，Co 的加入降低了相对密度，同时提高了磨头的硬度和磨削性能，并加强了基体的保持力。 但是，过大的夹持力可能会阻碍磨料颗粒的暴露，甚至在使用过程中导致打滑。