SEGMENTS OF A DIAMOND TOOL WITH COMPOUND STRUCTURE
FOR CUTTING OF HARD BRITTLE MATERIALS – AN APPROACH
TO THE CREATION OF “SMART SEGMENTS”
S. I. Tserman
and A. V. Belyakov
Translated from Novye Ogneupory, No. 11, pp. 52 – 58, November, 2016.
Original article submitted May 10, 2016.
Certain principles for the construction of the diamond component of segments of a cutting and grinding tool
for use in cutting of hard brittle materials, including refractories, are considered. Examples of constructions of
segments designed for a particular function are presented. Principles for the construction of compound “smart
segments” that exert additional effects in the cutting zone (besides cutting itself) which serve to adapt the cut
ting conditions to the tool are presented. Examples of cutting of different materials that demonstrate the uni
versality and efficiency of the proposed segments are presented.
Keywords: diamond tool, cutting zone, “smart segments,” fragmented segments”.
Enterprises involved in the production of articles from
hard brittle materials, in particular, refractories, often find it
necessary to subject the materials to mechanical treatment,
such as cutting, grinding, and drilling; fine treatment is also
sometimes necessary. A significant proportion of these oper-
ations are performed with the use of a diamond tool on a me-
tallic binder. Enterprises involved in the production of a cer
tain range of articles made from specific materials and that
possess a particular inventory of machine tools prefer a dia
mond tool that assures optimal cutting of a whole set of
worked materials with an optimal price : quality ratio. How
ever, in selecting particular treatment regimes the intensity
(speed) of the process does not always correspond to the de
sired level, and the universality of the tool may not coincide
with the range of worked materials.
In preceding studies we have developed segments by
means of which a diamond tool for high-speed treatment of a
broad range of materials may be created. The focus in these
research efforts was on taking into account phenomena that
occur in the cutting zone, i.e., the space between the cutting
and worked surfaces within their arc of contact as well as in
zones that are in direct contact with the diamond grains and
the material. Special features of such a complex and
multifactorial processes as diamond processing have been
described in a number of articles, for example [1, 2]. The
process involves fracturing of worked material (for example,
refractory) determined by the magnitude of the power load
on the material in the contact zone, the dependence of frac
turing of the diamond grains (wear) on the magnitude of the
power load on the diamond, and the kinetics of the wear pro
cess. An important role is played here by the composition of
the metal matrix (binder) supporting the diamond grains. The
processes that occur in the cutting zone lead to abrasive wear
of the binder and erosion of new diamonds for cutting, which
is one of the conditions for self-sharpening of a tool.
In order to estimate the efficiency of a tool we have to es
tablish a relationship between the rate of cutting of a particu
lar material and the rate of wear of the tool itself. For this
purpose we wish to propose a simplified conventional model
of the process. According to the model, mechanical energy
(P, W) distributed between the fracturing of the material (re
moval) through dispersion of its cutting grains and fracturing
of the diamonds in the course of their contact with the
worked part, enters the cutting zone. None of the other ac
companying phenomena, such as release of heat and ejection
of slurry from the cutting zone; abrasive wear of the binder,
or other effects are considered here in order to simplify the
model and isolate the influence of the selected factors and
Refractories and Industrial Ceramics Vol. 57, No. 6, March, 2017
1083-4877/17/05706-0618 © 2017 Springer Science+Business Media New York
From papers read to the International Conference of Refractory
Scientists and Metallurgists (April7–8,2016, Moscow).
OOO “Del’ta”, Group, “Adel” Co., Moscow, Russia.
FDBOU VO Mendeleev Russian Chemical and Technological
University, Moscow, Russia.