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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
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
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
H2 O → H+ + OH− (6)
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
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)
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.
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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