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This study aims to develop and evaluate an inexpensive and durable metal cutting wheel using thermal spraying and polymer binding to enhance the wheel’s cutting capability by bonding hard particles (abrasives) onto the wheel.

Thermal spraying was used to deposit the coating powder (chromium and silicon carbide) onto high carbon substrate. Wear loss and depth of cut as function of load, time and speed were evaluated on uncoated and coated wheel.

The coated cutting wheel performed better than the uncoated cutting wheel in terms of wear performance. However, the coated cutting wheel experienced coating peel off at higher load and cutting speed, leading to a decrease in wear resistance of the cutting wheel. Thus, optimally cutting should be performed either at low cutting speed and high load or at high cutting speed and low load to prolong the wheel’s lifetime.

The outcome of the study will be beneficial for academicians and industrial working on cutting wheel process.