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A study on wear mechanism and wear reduction strategies in grinding wheels


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Article  in  Wear · November 2003


DOI: 10.1016/S0043-1648(03)00078-4

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Wear 254 (2003) 1247–1255

A study on wear mechanism and wear reduction strategies


in grinding wheels used for ELID grinding
K. Fathima, A. Senthil Kumar∗ , M. Rahman, H.S. Lim
Department of Mechanical Engineering, National University of Singapore, Singapore 119260, Singapore
Received 7 August 2002; received in revised form 10 March 2003; accepted 1 June 2003

Abstract
Metal-bonded superabrasive diamond grinding wheels have superior qualities such as high bond strength, high stability and high grind-
ability. The major problems encountered are wheel loading and glazing, which impedes the effectiveness of the grinding wheel. Electrolytic
in-process dressing (ELID) is an effective method to dress the grinding wheel during grinding. The wear mechanism of metal-bonded grind-
ing wheels dressed using ELID is different form the conventional grinding methods because the bond strength of the wheel-working surface
is reduced by electrolysis. The reduction of bond strength reduces the grit-depth-of-cut and hence the surface finish is improved. The oxide
layer formed on the surface of the grinding wheel experiences macrofracture at the end of wheel life while machining hard and brittle work-
pieces. When the wheel wear is dominated by macrofracture, the wheel-working surface is free from loaded chips and worn diamond grits.
When the oxide layer is removed from the wheel surface, the electrical conductivity of the grinding wheel increases, and that stimulates elec-
trolytic dressing. The conditions applied to the pulse current influence the amount of layer oxidizing from the grinding wheel surface. Longer
pulse ‘on’ time increases the wheel wear. Shorter pulse ‘on’ time can be selected for a courser grit size wheel since that type of wheel needs
high grinding efficiency. Equal pulse ‘on’ and ‘off’ time is desired for finer grit size wheels to obtain stable and ultraprecision surface finish.
© 2003 Elsevier Science B.V. All rights reserved.
Keywords: ELID; Metal-bonded grinding wheel; Macrofracture; Grinding wheel wear

1. Introduction Wheel wear is an extremely complex process, which in-


volves the culmination of numerous wear events encoun-
Metal-bonded superabrasive grinding wheels are widely tered between many single grits and the workpiece. The
used to establish a mirror surface finish on hard and brittle conventional way of quantifying wheel wear is to express
materials. These wheels have characteristics such as high it as volumetric loss of material, which tells little about
bond strength and the potential for high grinding ratios, the wear mechanism. It is generally recognized that there
which make this suitable for ultraprecision grinding. How- are three main mechanisms of wheel wear: attritious wear,
ever, such wheels are susceptible to conditions known as grain fracture and bond fracture. Attritious wear involves
wheel loading and glazing, especially when fine abrasive dulling of abrasive grains and the growth of wear flats by
grains are used. Periodic dressing is essential to overcome rubbing against the workpiece. Grain fracture refers to re-
these difficulties and that makes the grinding process very moval of abrasive fragments by fracture within the grain,
tedious. and bond fracture occurs by dislodging the abrasive from
Recent developments such as on-machine truing and the binder. Binder erosion is caused by reduction of bond
in-process dressing of grinding wheels make the grinding strength and promotes grain dislodgment, especially with
process easier, and allow uninterrupted grinding. Elec- resin and metal-bonded wheels [6]. Attritious wear has the
trolytic in-process dressing (ELID) is an efficient method of smallest contribution to the decrease in volume but the wheel
dressing metal-bonded superabrasive grinding wheels using life is determined based on the attritious wear. Attritious
electrolysis. When the grinding wheel is subject to loading wear reduces the sharpness and the protrusion height of the
and glazing (‘catastrophic’ situation), the wheel is dressed grit, and it leads to wheel glazing, which is an indication of
automatically using electrolysis [1–5]. the end of wheel life.
Generally, the end of wheel life is indicated by excessive
forces, or by loss of finish, form, or size of the workpiece.
∗ Corresponding author. Tel.: +65-6874-6800; fax: +65-6779-1459. The end of wheel life is deduced by a skilled operator,
E-mail address: mpeask@nus.edu.sg (A. Senthil Kumar). or with the help of special sensors [7–9]. During ELID

0043-1648/$ – see front matter © 2003 Elsevier Science B.V. All rights reserved.
doi:10.1016/S0043-1648(03)00078-4
1248 K. Fathima et al. / Wear 254 (2003) 1247–1255

sified into difficult to machine materials. Finishing of these


Nomenclature materials with high accuracy and tolerance is of great chal-
ae wheel depth of cut (␮m) lenge in manufacturing industries. Recent studies explain
ag holding area of grit that the ductile mode grinding of hard and brittle material
Ag grinding area (grinding width × contact length) reduces the subsurface damage and improves the surface
(mm2 ) finish. The surface finish obtained from ductile mode grind-
ds diameter of the wheel (mm) ing is of submicron level, which completely eliminates the
E Young’s modulus requirement of finishing processes such as lapping and pol-
fg grinding force per grit ishing. But, ductile mode grinding could be achieved when
fh holding force per grit the deformed chip thickness approaches atomic size [11].
Fh total holding force The chip thickness is influenced by the factors such as the
Fn normal force properties of the material, the machining parameters and the
Ft tangential force grinding wheel conditions. The condition of defect free duc-
hmax maximum chip thickness or grit-depth-of-cut tile surface was reported by Bifano et al. [14]. The critical
(␮m) depth-of-cut to produce a defect free surface on hard and
H hardness brittle material is expressed as shown in the following equa-
Ip input power (A) tion:
   2
k ELID dressing constant E Kc
k1 constant related to wheel topography dc ∝ (1)
H H
k2 constant related to material properties
Kc fracture toughness The critical depth-of-cut solely depends on the properties of
Ls distance between the adjacent grits material to be machined. For BK7 optical glass, the critical
m material removal by electrolysis (mm3 /min) depth-of-cut is approximately equal to 45 nm. The maximum
N numbers of active grits per unit area chip thickness or grit-depth-of-cut, hmax , is expressed as
 
Rc current duty ratio (Ton /(Ton + Toff ) × 100) Vw ae
S sharpness factor depends on condition of the hmax = 2Ls (2)
Vc ds
grit (size and sharpness)
Toff pulse ‘off’ time (␮s) From the above expression, it is clear that the maximum chip
Ton pulse ‘on’ time (␮s) thickness depends on both machining and wheel parameters
Vc wheel peripheral speed (rpm) [12,13]. If the penetration depth of a single grit is less than
Vw work speed (mm/min) the critical depth-of-cut, the chip deformation takes place
plastically and that reduces the subsurface damages. Now
Greek letter the condition for ductile mode grinding can be expressed as
σs yield strength of the layer shown below:
hmax < dc (3)
The above condition can be obtained by controlling differ-
grinding, the wheel is redressed during the grinding oper- ent machining parameters during grinding. For example, the
ation. The wheel wear must be compensated in order to increase of wheel speed or reduction of depth-of-cut reduces
obtain high accuracy and tolerance. If the wheel is dressed the chip thickness but, it needs special machines or special
prior to the end of wheel life, the wear rate will increase, attachments. Recent studies show that ductile mode could
and if it occurs later the workpiece surface will be affected. be achieved using the conventional machine with the su-
The dressing intervals should be selected in a way that bal- perabrasive grinding wheels and the ELID. The superabra-
ances better grinding performance with reasonable wheel sive wheels reduce the distance between the adjacent grits
wear. The authors reported in their previous studies [10] (Ls ) and minimize the chip thickness. But, there is no ex-
that an oxide layer formed on the grinding wheel surface planation about the significance of bond strength and bond-
during ELID, when the oxide layer breaks it causes some ing mechanism during ELID grinding. The relation between
instability on grinding parameters. The separation of the ox- the bond strength and the mode of material removal using
ide layer from the wheel surface stimulates electrolysis and metal-bonded diamond pellets of different hardness was an-
thus the wheel is redressed. While performing the grinding alyzed by Izumitani [15], and the results concluded that the
operation, the surface of the wheel is wet and soft. Hence mode of material removal varies from fracture to plastic
direct methods of measuring wheel wear become difficult scratching based on the hardness of metal bond.
and a non-contact measurement of wheel profile is desired. The ELID is influenced by the electrical parameters cho-
Nano-surface finish is of particular interest in optical, sen for the dressing operation. The electrical parameters such
electrical and semiconductor industries. The materials used as voltage, current and current duty ratio (Rc ) influence the
in these industries such as glass, ceramic and silicon are clas- wheel topography and the wear mechanism of metal-bonded
K. Fathima et al. / Wear 254 (2003) 1247–1255 1249

grinding wheels. There is no known previous research ex- A standard grinding coolant (CG-7: NUXES) was diluted
plaining of the wear mechanisms, end of wheel life, and the in water with a ratio of 1:50, and used as an electrolyte and
dressing interval during ELID grinding. Therefore, the main coolant for the experiments.
objective of this study is to analysis the wheel wear mech- BK7 glass of 80 mm diameter and 10 mm thick was
anisms, and to develop control strategies for ELID. mounted vertically on the machine table as illustrated in
Fig. 1. The glass surface was made flat by ground the
surface using cast iron-bonded diamond grinding (CIB-D)
2. Experimental setup and procedure wheel of grade #325, which produced an initial surface
roughness of 0.534 ␮m. Vertical grooves were ground on
A schematic illustration of the experimental setup is the glass surface using CIB-D wheel of grade #4000. Dur-
shown in Fig. 1. The experiments were carried out on a ing grinding vertical groove, the contact area between the
computerized numerical control (CNC) machining cen- grinding wheel and the workpiece increased at every depth
ter with a feed accuracy of 1 ␮m. The ELID is a simple of cut per pass. The increase of grinding area within a
and efficient technique that can be easily adopted for any small volume of material removal made it easy to study the
conventional machine. The basic ELID system consists of topographical changes of the grinding wheel. Each vertical
a metal-bonded diamond grinding wheel, an electrode, a groove was ground until a total depth of cut of 250 ␮m. The
power supply and an electrolyte as illustrated in Fig. 1. The dynamometer (Model 9256Al: KISTLER) was fixed be-
metal-bonded grinding wheel was made into a positive pole tween the angle plate and the workpiece. The normal force,
through the application of a brush smoothly contacting the tangential force and the dressing current were recorded us-
wheel shaft. An electrode made of copper, covering 1/6 of ing a data recorder (PC208Ax: SONY) and stored in a PC
the grinding wheel perimeter was connected to the nega- through a data acquisition system.
tive pole. A straight type metal-bonded diamond grinding The spindle rotation was detected using a fiber optic sen-
wheel was mounted on a vertical spindle and the gap be- sor as seen in Fig. 1. The grinding wheel profile with respect
tween the grinding wheel and the electrode was adjusted to to the wheel rotation was measured using the developed
approximately 0.1–0.3 mm. In the small clearance between non-contact profile sensor. The optical sensor that uses the
the positive and negative poles, electrolysis occurs through principle of photoelectric effect is illustrated in Fig. 2(a).
the supply of the grinding fluid and an electrical current. When the grinding wheel moves in between the LED and
An electric current in the form of square pulse wave was phototransistor, the light from LED is interrupted and the
supplied from the ELID power supply (FUJI ELIDER 921) change of light intensity is measured in the form of electric
to the positive and negative poles. The peak current (Ip ) and current by the phototransistor. The calibrated displacement
voltage can be varied 1–10 A and 30–90 V, respectively. output characteristic of the sensor is shown in Fig. 2(b). The
The Ton and Toff time can be varied from 1 to 10 ␮s by liner range from 3 to 9 V are chosen for measurement and
using the timer switch provided on the ELID power supply. the reference point is always set at the output of 6 V. The

Fig. 1. Experimental setup.


1250 K. Fathima et al. / Wear 254 (2003) 1247–1255

H2 O → H+ + OH− (6)

Fe2+ + 2OH− → Fe(OH)2 (7)

Fe3+ + 3OH− → Fe(OH)3 (8)

These reactions continue until the non-conductive oxide


layer (Fe2 O3 ) is formed on the surface of the grinding
wheel. The non-conductive oxide layer deposition on the
grinding wheel surface prevents the bonding material from
further oxidizing, which was noticed by the constant dress-
ing current and voltage. The oxide deposition on the grind-
ing wheel surface produces non-linear electrolysis [16]. The
non-linearity was found while using cast iron-bonded grind-
ing wheels. The volume of metal oxide at wet condition
is more than the volume at dry condition, which increases
the diameter of the grinding wheel after pre-dressing.
Fig. 3(a) shows the profile of a grinding wheel after tru-
ing and after pre-dressing. The diameter of the grinding
wheel was increased about 200 ␮m after pre-dressing. An-
other verification was conducted by compared the dressed
and the undressed portion of the grinding wheel. Fig. 3(b)
shows the profile of a partially dressed (without rotat-
ing the wheel) grinding wheel using ELID. The dressed
portion of the grinding wheel shows an increase in di-
ameter than the undressed portion. The increase of wheel
diameter after pre-dressing shows that the active grits are
bonded in the metal oxide matrix rather than the bonding
Fig. 2. Measurement of wheel profile using profile sensor. material.
The significance of bonding mechanism and its influ-
ence on grinding parameters were studied by compar-
profile of the grinding wheel is measured before and after ing the grinding forces between ELID and conventional
each grinding experiment to investigate the change of wheel grinding processes conducted at similar machining and
diameter and shape. dressing conditions. During conventional grinding, the
grinding wheel was pre-dressed and dressed periodically
using electrolysis. The ELID grinding was performed at a
3. Results and discussions dressing condition of 60 V, 10 A and pulse width of 10 ␮s
(Ton = 5 ␮s, Toff = 5 ␮s). The machining conditions were:
feed rate 200 mm/min, spindle speed 3000 rpm and depth
3.1. Bonding mechanism of diamond grits during ELID
of cut 1 ␮m per pass. Fig. 4 shows the average normal
and tangential forces recorded during ELID and conven-
CIB-D grinding wheel of 75 mm diameter, 3 mm width
tional grinding processes, respectively. The normal and
with an average grit size of 4 ␮m (#4000) and grit concen-
tangential forces were found to be minimized with the
tration of 100 was trued with an accuracy of 3 ␮m using
application of the ELID. The average surface roughness
on-machine electrodischarge truing (EDT). Then the grind-
of ground surfaces measured using Talysurf (Series 120)
ing wheel is pre-dressed using ELID in order to achieve
with the stylus of diameter 2 ␮m were found to be 0.007
enough grit protrusion. The pre-dressing conditions were
and 0.154 ␮m for ELID and conventional grinding process,
90 V, 10 A, pulse width of 10 ␮s (Ton = 5 ␮s, Toff = 5 ␮s)
respectively.
and spindle speed of 1000 rpm. At the beginning of the
The maximum chip thickness calculated according to
electrolysis, the current passes through the electrolyte and
Eq. (2) for the above machining condition was found to be
converts the metallic irons into oxides or hydroxides. The
approximately 100 ␮m, which is greater than the critical
electrochemical reaction for a cast iron-bonded grinding
depth-of-cut for the glass material. But, the result obtained
wheel is expressed as follows:
using ELID grinding shows a P–V surface roughness of
Fe → Fe2+ + 2e− (4) 27 nm, which is less than the critical depth-of-cut of glass
material. From the above experimental result, it is clear
Fe → Fe3+ + e− (5) that the hmax during ELID is also influenced by the bond
K. Fathima et al. / Wear 254 (2003) 1247–1255 1251

Fig. 3. Grinding wheel profiles and surfaces before and after dressing using ELID.

strength of the grinding wheel. The hmax for the ELID 3.2. Wear mechanisms of grinding wheel during ELID
grinding can be written as shown below:
  When the bond strength of the wheel-working surface is
Vw ae
hmax = 2kLs (9) reduced by electrolysis, the mechanisms of wheel wear, the
Vc ds
end of wheel life and the phenomena of in-process dressing
where k is the ELID dressing constant and are needed to be analyzed in order to utilize the grinding
k ∝ Ip , V, Rc (10) wheel efficiently. When the diamond grit performs grinding,
there are two major forces that are acting opposite to each
Change in any one of the above parameters affects the thick- other on the grit. They are the maximum grit holding force
ness and the strength of oxide layer formed on the grind- exerted by the bond strength (fh ) and the grinding force per
ing wheel surface. A set of experiments was conducted by grit (fg ). Fig. 5 shows the different states of grit–workpiece
changing the current duty ratio (Rc ) with a constant cur- interaction based on the condition of forces during grinding.
rent intensity (constant Ip and V) shows that the increase of Normally the grinding wheel surface consists of diamond
Rc increases the thickness of oxide layer and decreases the grits at different conditions such as dislodged grits, worn
bond strength at the wheel-working surface. Grinding with out grits and sharp grits. For the dislodged grits, the holding
thicker layer produces smoother surface finish than grinding force fh is lower than fg , so that the grit cannot penetrate into
with thinner oxide layer. From the experimental results, it is the workpiece. If the grit cannot penetrate into the work, it
clear that the grit-depth-of-cut during ELID can be varied is removed from the bond matrix due to the hardness of the
by varying the bond strength. workpiece, while grinding as illustrated in Fig. 5(a) [17].
1252 K. Fathima et al. / Wear 254 (2003) 1247–1255

as seen in Fig. 5(c). At this stage, the percentage of grits


on wheel-working surface is dominated by the worn out
grits, which promotes the crack propagation throughout the
wheel-working surface and creates a macrofracture from the
grinding wheel surface. When the insulating outer layer is
separated from the wheel-working surface due to macrofrac-
ture, the electrical conductivity of the grinding wheel in-
creases and that stimulates ELID.
Assuming the grinding wheel profile is uniform with equal
grit protrusion and there are N numbers of active grits per
unit area, the total holding force can be approximated as
Fh = Nfh Ag (13)

When the force per grit is resolved into normal and tangential
components, the total normal and tangential forces can be
expressed as
Fn = Nαfg Ag (14)

Ft = Nβfg Ag (15)

where α, β are the normal and tangential force components


of fg , and Ag the total grinding area.
The condition of macrofracture from the wheel or the
wheel end of life can be expressed as when
Fn > Fh (16)

To verify the above phenomena, a vertical groove was


ground on BK7 glass using CIB-D grinding wheel of grade
#4000. The force components and the dressing current
were recorded with respect to the spindle rotation. The ma-
chining conditions were: spindle speed 3000 rpm, feed rate
200 mm/min and depth of cut 1 ␮m per pass. The wheel
dressing conditions were 90 V, 10 A and pulse width of
10 ␮s (Ton = 5 ␮s, Toff = 5 ␮s). Fig. 6(a)–(c) shows the
Fig. 4. Average normal and tangential forces during ELID and conventional
processes. normal force, tangential force and dressing current during
ELID grinding, respectively.
The drop in dressing current during the air cut region
For a sharp grit, fh is greater than fg and the grit penetrates shows that the wheel surface contains thick oxide layer that
and cut the workpiece material (Fig. 5(b)). The depth of resists the flow of current. The increase of grinding forces
penetration depends on the condition of the grit, i.e. the from point A to B shows the condition of instability of
sharpness and the size of the grit. Now, the holding force the grinding wheel. The pre-dressed wheel surface contains
and grinding force for a single grit during ELID grinding large amount of dislodged grits, which can be identified by
can be expressed as shown below: larger protrusion from the wheel surface. When the wheel
contacts the workpiece, the dislodged grits are removed
fh = k1 σs ag (11) from the grinding wheel surface that reduces the grit density
fg = k2 Shmax (12) at the beginning stage and it increases the normal grinding
force at the beginning of grinding as seen in Fig. 6(a). After
where k1 is the constant related to wheel topography, k2 the the point B, normal force is found to be more stable and it
constant related to material properties, S the sharpness factor shows that the wheel surface is in a stable condition. After
depends on condition of the grit (size and sharpness), ag the the point C the normal grinding force gradually reduces
holding area of grit, and σs the yield strength of the layer. and started increasing gradually once again. This kind of
The grinding force of the grit gradually increases dur- phenomena repeats throughout the grinding process, and
ing grinding because of the grit wear. When a worn out the cyclic time becomes longer or shorter depending upon
grit performs grinding, the fg exceeds fh and the force ex- the material removal per pass. When the normal force starts
erted on the grit produces cracks on the bonding matrix decreasing, a sudden increase of tangential force is noticed,
K. Fathima et al. / Wear 254 (2003) 1247–1255 1253

Fig. 5. States of diamond grit during ELID.

Fig. 6. The normal force, tangential force and dressing current during ELID process.
1254 K. Fathima et al. / Wear 254 (2003) 1247–1255

and it retains only for the few cycles. The increase of dress-
ing current during the above cycle shows the occurrence
of ELID of the grinding wheel. Similar cycles repeat in
between the points D, E and F, which shows the wheel end
of lives and the in-process dressing cycles.
Fig. 7 shows the profile of the grinding wheel before and
during breakage. The profile of the wheel was recorded at
the same reference point, i.e. at 6 V in order to compare the
wheel profile, and a radial wear of 37 ␮m was recorded. The
wheel profile measured before breakage shows to be almost
flat without much grit protrusion. The profile during break-
age shows an irregular profile that explains the separation of
oxide layer happened segment by segment from the wheel
surface.

3.3. Control of wheel wear

According to Faraday’s law of electrolysis, the amount


of material removal is proportional to Ip and Ton time:
m ∝ Ip Ton (17)

Increase of Ip and Ton increases the wheel wear if the elec-


trolysis is linear. But, the ELID uses non-linear electrolysis
that produces a self controlled oxide layer that prevents
excessive bond erosion. The main disadvantage of the
non-linearity is the macrofracture of the oxide layer. If the
thickness of layer removed from the wheel surface during
macrofracture is more than the grit size of the grinding
wheel, the sharp new diamond grits are also removed along
with the fractured layer. This will increase the reduction of
wheel diameter and increases the wastage of diamond grits.
An attempt is made to control the macrofracture by con-
Fig. 7. Grinding wheel profiles before and during breakage. trolling the electrolysis based on the grit size of the grinding
wheel. The first step is the control of pre-dressing time

Fig. 8. Radial wear vs. Ton time.


K. Fathima et al. / Wear 254 (2003) 1247–1255 1255

with respect to the grit size of the grinding wheel. If the wheel life and it increases the electrical conductivity of
metal-bonded wheel is pre-dressed for a longer time, the grinding wheel, which stimulates electrolysis.
strength of the wheel-working surface is reduced and that 4. Reduction of Ton time reduces the amount of oxidiza-
increases more bond fracture at the beginning of grinding. tion/breakage of layer from the grinding wheel surface
The requirement and the function of the course and fine grit and reduces the radial wear. Shorter Ton time is prefer-
size wheels are different. Courser grit size wheel requires able for courser grit size wheels that need higher grind-
high grinding ratio while the finer one needs better grain ability. Fine polishing of surfaces could be achieved by
protrusion and grit density. The recommended pre-dressing finer grit wheels with longer Ton time.
times are 5–10 and 20–30 min for finer (#4000 and more)
and courser (#325 and below) grit size wheels, respectively.
The second step is the control of wheel wear during References
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