How to choose diamond rotary dresser for dressing gear grinding wheel?

What is diamond roller?

The diamond roller is a high-efficiency, high-life, low-cost grinding wheel dressing tool that uses electroplating or powder metallurgy to embed a large number of diamond particles on the surface of a steel roller. It is used for special machine tools and gear grinders for large-scale forming grinding.

Rotating at a certain speed (to reduce the relative speed between the roller and the grinding wheel), the high-speed rotating grinding wheel surface is ground and rolled, so that the grinding wheel obtains a sharp working surface that matches the roller profile.

Common diamond rollers can effectively replace single crystal diamond pens to dress grinding wheels, greatly improving their production efficiency and increasing the surface quality and precision of the processed parts.

There are three types of diamond rollers: sintered diamond rollers, electroplated diamond rollers and CVD diamond rollers. Each type of diamond roller has different advantages and disadvantages, and the application industry is also different.

(1) Sintering method: divided into hand-planted sintered rollers and randomly distributed sintered rollers, with strong durability;

(2) Electroplating method: high-precision production of small and complex rollers;

(3) CVD roller: good dressing effect on CBN grinding wheels.

According to different application scenario requirements, diamond roller dressing processes are divided into two types: cut-in diamond roller dressing and pendulum diamond roller dressing. Because cut-in diamond roller dressing is simpler than pendulum diamond roller dressing, it is more widely used in actual production.

Cut-in diamond roller dressing process: the forming roller is used to dress the forming grinding wheel. The diamond roller and the grinding wheel profile to be dressed are exactly opposite. The diamond roller is driven by a motor to rotate and the grinding wheel is subjected to a short-stroke radial cut-in motion, thereby achieving the dressing of the grinding wheel; the cut-in diamond roller can produce various complex forming surfaces.

Cut-in diamond rollers are widely used in automotive parts, engines, bearings, textile machinery, guide rails, lead screws, measuring tools and other industries.

Pendulum diamond roller dressing process:

The diamond roller is dressed by feeding, that is, the diamond roller movement trajectory is controlled by CNC programming to dress the grinding wheel to the required forming surface. The simple procedure is: fast feed (cannot touch the gear) – slow feed (feed at the required cutting speed) – light repair – exit.

Pendulum diamond roller dressing is widely used in the gear industry.

Among the choices of high-precision gear processing methods, grinding to achieve the target accuracy is currently a relatively wide choice. In the grinding process, the grinding wheel itself often causes deviations in gear accuracy. At this time, the importance of dressing tools is highlighted. Diamond dressing rollers are indispensable precision tools in gear grinding. They ensure the shape and accuracy of the grinding process by maintaining the best condition of the grinding wheel.

Function of diamond dressing roller
Dressing grinding wheel:
Diamond dressing roller is used to dress the shape and surface of grinding wheel. Since the grinding wheel will wear, deform or become blocked during the grinding process, the diamond dressing roller can reshape the geometry of the grinding wheel to ensure that it maintains the best cutting performance.
Improve grinding accuracy
Accurate grinding wheel shape is essential for the grinding accuracy of gears. Diamond dressing rollers can improve the overall accuracy of the grinding parts by accurately dressing the grinding wheel to ensure that the geometric features such as gear tooth shape, pitch and top arc meet the design requirements.
Improve the quality of the processed surface:
By effectively dressing the grinding wheel, diamond dressing rollers can help reduce the surface roughness during the processing process and improve the finish and quality of the gear surface.

Features of diamond dressing rollers
(1) High hardness and wear resistance
As the hardest material in nature, the hardness and wear resistance of diamond enable diamond dressing rollers to maintain a stable dressing effect for a long time and still perform well under high load and high temperature conditions.
(2) High-precision machining
Diamond dressing rollers usually have a high-precision manufacturing process, which can provide a detailed dressing effect and ensure the accuracy and consistency of the grinding wheel.
(3) Strong adaptability
Diamond dressing rollers can be customized according to different grinding requirements and grinding wheel characteristics, such as different grain sizes, shapes and specifications to adapt to various gear grinding processes
Application areas

Diamond dressing rollers are widely used in automotive, aerospace, mold manufacturing, and other fields, especially in occasions where high-precision gear machining is required.
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