An investigation into the challenges of the point grinding machining process

Point grinding is an abrasive machining process that utilises miniature single layer superabrasive tools to remove material. The use of such small diameter tools offers advantages in the manufacturing of small or difficult to access complex 3D geometries, however, in their current state, these tools suffer from several critical challenges preventing their successful implementation. An investigation into the use of a typical commercially available point grinding tool for machining of hardened steel components has been carried out, with the aim of identifying the critical process challenges. The requirement for high rotational speeds, high tool deflection, variation in grit protrusion heights and bond layer thickness, accelerated tool wear, increased sensitivity to runout, zero cutting speed at tooltip and high tool loading have been identified as the main issues affecting the point grinding process. It is crucial that these challenges are correctly understood to facilitate future tool development.