Novel tool design to tailor debris migration and tool wear mechanism in micro-slot grinding

Wear debris entrapment or loading is a major problem with polycrystalline diamond (PCD) micro-grinding tools. This paper reports a step change in the performance of PCD micro-tool when square micro-pool array is fabricated on its secondary surface. The investigations on BK7 glass micro-slot grinding revealed that the proposed tool design with micro-pool array undoubtedly performs better in comparison to other tool, with reference to reduced cutting forces (by 30–48%), efficient debris disposal, improved surface finish (by 3 times) and tool utilization time (by 66%). Tool design and cutting force reduction are well justified and supported with analytical analysis of undeformed chip thickness and cutting forces.