Rotary dressing tool

The method of constructing a rotary dressing tool comprising the steps:

• forming three or more sintered polycrystalline synthetic diamond segments by pre-profiling the cutting surface of said segments to the dimensional requirements of the part piece to be ground, using a traveling wire e.d.m., and
• forming a molding ring of aluminum or high grade graphite, whose inside perimeter has been machined on a lathe to the negative profile of said part piece to be ground by said abrasive wheel, and
• radially placing said three or more sintered polycrystalline synthetic diamond segments symmetrically about the inner perimeter of said molding ring, in the formed area machined therein, holding said profiled segments in place temporarily with an electrically conductive adhesive or a five minute epoxy, and
• placing diamond particles in said molding ring, with an anode nickel cup in the center, and by means of a centrifuge randomly dispersing said diamond particles about the inside periphery of said molding ring where said diamond particles become attached by an electrically deposited nickel binder, and
• placing said molding ring in a conventional nickel plating tank where said molding ring remains for an extended period of time, under low direct current, to build a matrix of abrasive resistant nickel based alloy approximately 0.200 inches in thickness, forming a permanent bond in and about said dispersed diamond particles and said profiled segments, and
• placing a cylindrical metal core, preferably of stainless steel, in the center of said molding ring and mechanically bonding said cylindrical metal core to said matrix by injecting a filler of molten solder or plastic material into the space between the inside perimeter of said molding ring and the outer circumference of said cylindrical metal core, and
• surface grinding said tool to true up the sides of said tool so that said sides are perfectly parallel with respect to each other, and
• machining said cylindrical metal core to create a bore hole which is concentric and square with respect to the diamond cutting surface of said rotary dressing tool, and
• removing said molding ring from the exterior perimeter of said rotary dressing tool by turning said molding ring in a lathe, and
• running the circumferential surface of said rotary dressing tool into a grinding wheel to expose said diamond particles and said sintered polycrystalline synthetic diamond segments down to their working surfaces.