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Types of Profile Dressing Rolls

The production of high-precision diamond dressing rolls with very narrow tolerances is only possible by mean of so-called galvanic negative methods. In a galvanic negative shaping, the diamonds are distributed stochastically on the profile surface.

So formed this diamond layer is supported by metal matrix and represents the later roller surface. Only this manufacturing process, which is used in diamond dressing rolls (also in combination with other methods), enables particularly tight tolerances without reworking - even with very small radii.

Diamond dressing rolls are available in the following versions:

Diamond Distribution 100% -Stochastic

In this type, the grain distance is determined by the diamond grain size used. The diamond grain size, in turn, results from the specific application, from the required roughness of the surface and the smallest convex radii of the workpiece. Due to the method, the diamond grains are distributed stochastically (arbitrarily) on the later surface of the dressing roll, thereby achieving the densest diamond occupation. This dressing roller type always has larger diamond content than comparable hand-held rollers.

The shape and dimensional accuracy of the diamond dressing rollers is basically achieved without reworking the diamond coverings, since rework requires a loss of life. Concave radii of 0.025 mm and convex radii of 0.1 mm are possible. Almost all profile shapes can be produced.

abrichtrolle_oberflaeche_diamantenverteilung Types of Profile Dressing Rolls

Picture 1: The surface of a galvanically negative bounded ROTMESS dressing roller. The grain distribution is 100% stochastic.

Stochastic Diamond Distributions with Hand-Set Areas

This version corresponds to the upper type, but in some “critical” areas the diamonds can be hand-set. This embodiment is required when the profile to be produced consists of cylindrical parts with high "shoulders". 

The larger hand-set diamonds on the "shoulder" increase the actual surface roughness of the grinding disc. The danger of overheating when grinding is thereby substantially reduced in this area.

dressing_roll_handset_diamond Types of Profile Dressing Rolls

Picture 2: Scheme of a profile dressing roll with partially hand-set diamonds.

 Furthermore,  little synthetic diamond tile can be inserted manually for the edges reinforcement or to achieve the sharp edges on the grinding wheel.

abrichtrolle_oberflaeche_handgesetzt Types of Profile Dressing Rolls

Picture 3: The surface of a galvanically negative bounded ROTMESS dressing roller. The edges are reinforced with little synthetic diamond tile.

Dressing Rolls with 100% Hand-Set Diamonds

This version is only used for very special workpiece geometries. In this particular manufacturing process, the diamonds are manually inserted into the mold ring according to a certain scheme. Because of the use of an adhesive to fix the diamonds the achievable tolerances are lower. However, the dimensional deviations are usually less than 0.1 mm. Due to the bigger diamonds used, however, many profile shapes cannot be produced.



C.I.F. A58033341



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