Mechanisms of surface response to overlapped abrasive grits of controlled shapes and positions: An analysis of ductile and brittle materials

Abrasive surfaces can nowadays be produced incorporating precision cutting features of controlled shape, size, protrusion and location. This study investigates the influence of defined abrasive shapes (square/triangular/conic pyramidal frusta) of designed groups of overlapped abrasives on the successive removal of ductile (Cu) and brittle (Al2O3) materials. Scanning electron microscopy studies combined with detailed micro-topographical evaluations of scratches/adjacent material have revealed the progressive actions of material removal/displacement of copper and the fracture and brittle/plastic transitions of sapphire for the different abrasive shapes, aiding a fundamental understanding of the influence of defined micro-geometries on the grinding process and resulting material surface topography.