Development of an ultrathin BD-PCD wheel-tool for in situ microgroove generation on NAK80 mold steel

► Two in situ techniques comprising 'reverse RWSE' and 'HSFSG' are developed successfully. ► The grinding-edge of a BD-PCD wheel-tool can be thinned to an edge-thickness of 5-μm. ► Microgrooves of desirable surface integrity are generated on NAK80 mold steel. ► Using nanometric depth grinding creates considerable metal removal rates and low tool wear. ► The methods really overcome the traditional impediments to using diamond to grind steel.