Why Dressing. Pushing. Free penetrating
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- Garry Morrison
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1
2 Why Dressing Pushing Free penetrating
3 Dressed Blades Versus Non Dressed Blades High loads Low diamond exposure Low machinability High diamond exposure High machinability
4 Dressing Dressing = Exposing diamonds and releasing partially embedded diamonds Diamonds not exposed Diamonds exposed after dressing
5 Improving Concentricity of blade edge to spindle rotation Dressing
6 Dressing Shaping the edge geometry: Angled cut - Flat edge Flat edge - Special geometry: (-V-, Others) -V- edge
7 Electro polishing - nickel blades Dressing Methods Power supply Etching solution Blades
8 Cont. Electro polishing - nickel blades Dressing Methods Nickel blade 17mic. Grit - 330x / 1000x after Electropolishing Nickel blade 17mic. Grit - 100x after Electropolishing Nickel blade 17mic. Grit - 100x After fine grinding with a Si. Ca. wheel
9 Dressing Methods Cylindrical grinding: Blade Silicon Carbide wheel
10 Dressing Methods Cont. Cylindrical grinding: Sil. Car. Grinding wheel Blade Flange Arbor
11 Dressing Methods
12 Profile Grinding Sil. Car. Grinding wheel Blade
13 Dressing / Grinding Machine
14 Dressing / Grinding Machine
15 Dicing Dressing Media's Silicon Carbide / 600 / 800 mesh Silicon Others - Glass, Ceramic Diamond plates (For resin single & gang ass.)
16 Not needed in most cases - Self re-sharpening blade Dressing Resinoid Blades High temperatures Resin Blade wear Diamond
17 Dressing Resinoid Blades Lapping to open the blade side surfaces: For applications requiring very straight / perpendicular cuts Carriers Blades Double plate Lapping Machine Top plate Bottom plate
18 Dressing Resinoid Blades Cont. Example of a thick PZT application: 15.5mm cut depth
19 Dressing Metal Bond Blades Hard and sharp edges Diamond (Blocky) Hard Nickel Or metal sintered
20 Dressing Metal Bond Blades Dressing with dressing media s on the saws: Dressing media
21 General dressing methods on the saw Cleaning powder residue to expose the diamonds Machining off blade binder to expose diamonds Diamonds not exposed Diamonds exposed after dressing
22 General dressing methods on the saw Cont. Flattening the blade edge Before After - Lower the spindle RPM - Use multiple shallow cuts - Use slow feed rates
23 On Line Dressing After each cut the blades is passing a dressing media. Substrate Sil. Carbide or Al. Oxide Dressing Stick. Feed
24 Re - Dressing During the Dicing Process Powder residue from the dicing Blade edge
25 Dressing on the dressing station Nickel / Diamond Electroforming 17, 30 & 50 mic. grit Silicon Carbide 600 mesh Chuck Dressing station
26 Dress station using a Nickel / Diamond media Designed only for dressing resinoid blades Should be used in a dicing mode not a chop mode
27 Dress station using a nickel /diamond media Dressing media Nickel & Diamonds Chopping mode Z movement Only Resinoid Single diamonds in contact with the blade edge Binder - Nickel Blade edge with a copy of the diamonds geometry
28 Simulating the Chop mode Metal file Chop mode Shaping mode
29 Dress station using a nickel /diamond media Z Copping mode Wrong process Resinoid Edge defects due to high loading Dressing media Nickel & Diamonds
30 Dress station using a nickel /diamond media Stationary Z Resinoid Wear of blade edge Resinoid Y - Movement mm
31 Dress station using a nickel / diamond media Cont. Profile images of in Line Dressing Resin - 56 mm O.D. - P/N C QUP -W- Before After Dressing media P/N D X3 30mic grit Spindle Speed 18 Krpm Feed rated 5mm/sec Cut depth mm on each pass No. of cuts to achieve a flat blade edge 5x
32 Dressing station with nickel / diamond media Cont. Profile images of in Line Dressing Resin 4.6 O.D. - P/N QUP -W- Before After Dressing media P/N D X3 30mic grit Spindle Speed 8 Krpm Feed rated 5mm/sec Cut depth mm on each pass No. of cuts to achieve a flat blade edge 5x
33 Dressing station with nickel /diamond media Dressing a metal bond blade on a nickel / diamond dressing media: Nickel or Metal sintered Blade binder Diamonds remaining in contact with diamonds Damaged diamonds Nickel / diamond dressing block
34 Dress station using a Silicon Carbide media Designed for light / moderate dressing Used similar to standard dressing media which is mounted on the chuck To clean powder residue on metal or resin type blades Can be used for flattening blades edges, mainly resinoid - (Slower mode)
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