Feasibility Study on Near-Dry Electrical Discharge Dressing of Metal Bonded Diamond Grinding Wheels

2009 ◽  
Author(s):  
Y. Jia ◽  
C. J. Wei ◽  
B. S. Kim ◽  
D. J. Hu ◽  
J. Ni
Keyword(s):  
Electrical Discharge ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Wheel Surface ◽  
Rotating Speed ◽  
Diamond Grinding ◽  
Electrode Shape ◽  
Experimental Parameters ◽  
Discharge Parameters ◽  
Electrical Discharge Dressing

Diamond grinding wheels are important tools to carry out precise or ultra-precise grinding of difficult-to-machine materials; however, the difficulty of dressing diamond grinding wheels is a bottleneck problem in their wide application. The objective of this study is to identify the feasibility of near-dry electrical discharge dressing (EDD) of metal bonded diamond grinding wheels. Through design of experiment (DoE), sets of tests were carried out to select proper dielectric mist composition and electrode material, to quantify the dielectric mist composition, to choose the electrode shape and rotating speed, and to investigate the influence of electric discharge parameters on dressing performance. By applying optimized experimental parameters to near-dry EDD of metal bonded diamond grinding wheels, more diamond grits protruded out of the grinding wheel surface, and the worn diamond grinding wheel got sharpened.

Electrical Discharge Dressing Metal-Bonded Diamond Grinding Wheels with Misted Emulsion

2013 ◽  
Vol 313-314 ◽  
pp. 785-789 ◽  
Author(s):  
Lan Rong Cai ◽  
Wen Yu Ruan ◽  
Min Li
Keyword(s):  
Electrical Discharge ◽  
High Hardness ◽  
Processing Parameters ◽  
Diamond Wheel ◽  
Grinding Wheel ◽  
Three Dimension ◽  
Grinding Wheels ◽  
Diamond Grinding ◽  
Before And After ◽  
Electrical Discharge Dressing

Preparation of superabrasive grinding wheels presents severe challenges due to the high hardness of abrasive grain. In this paper, electrical discharge dressing (EDD) technology with misted emulsion is applied to dressing bronze-bonded diamond wheels. Dressing experiments were carried out. The wheel profiles before and after dressing were measured using a Dektak 6M profilometer. The diamond wheel surface topographies before and after dressing were observed by three-dimension digital microscope. In addition, the performance of EDD’ed wheel was evaluated in practical grinding. It is shown that favorable surface topography can be obtained under suitable processing parameters and EDD misted emulsion with is feasible for metal-bonded diamond grinding wheel.

scholarly journals Grinding efficiency and profile accuracy of diamond grinding wheels dressed with wire electrical discharge conditioning (WEDC)

2021 ◽  
Author(s):  
Ali Zahedi ◽  
Jahangir Khosravi ◽  
Bahman Azarhoushang
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Wear Behavior ◽  
Process Time ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Electrically Conductive ◽  
Plunge Grinding ◽  
Specific Grinding Energy ◽  
Diamond Grinding

AbstractSuper abrasive diamond grinding wheels are the most promising tools for the precision machining of advanced ceramics and carbide materials. However, the efficiency of conventional conditioning of these tools is limited owing to high dressing tool wear, long process time, low form flexibility, and induced damage to the abrasive grains. Wire electrical discharge machining (WEDM) is an alternative method for conditioning of superabrasive grinding wheels with electrically conductive bonding materials. In this study, cylindrical plunge grinding of an alumina ceramic with a resin-bonded diamond grinding wheel is investigated. The assigned type of resin bond contains copper particles and is accordingly electrically conductive for wire electrical discharge conditioning (WEDC). Conventional (mechanical) and WEDC methods are used for generating the same profile on two similar diamond grinding wheels. As a result, the specific grinding energy was reduced up to 26% and 29% during rough and finish plunge grinding, respectively. Reduced specific grinding energy and forces, along with more effective grain protrusion and sharpness by using WEDC for profiling of grinding wheels, have contributed positively to the ground surface conditions despite the relatively rougher wheel surface topography in comparison to the conventional profiling. The more considerable reduction in the mean roughness depth (Rz) than in the arithmetical mean roughness value (Ra) (11% smaller Rz values in WEDC versus mechanical conditioning) verifies that the workpiece surface underwent less surface degradation in case of WEDC because of smaller grinding forces. Furthermore, the profile wear behavior of the workpiece ground with the WED conditioned grinding wheel was superior to the conventionally conditioned one.

Application of Fractal Theory in Electro-Discharge Dressing Diamond Grinding Wheel

2012 ◽  
Vol 430-432 ◽  
pp. 449-452
Author(s):  
Lan Rong Cai ◽  
Yang Li ◽  
Min Li
Keyword(s):  
Fractal Dimension ◽  
Surface Morphology ◽  
Simulation Model ◽  
Electrical Discharge ◽  
Fractal Theory ◽  
Grinding Wheel ◽  
Peak Current ◽  
Diamond Grinding Wheel ◽  
Diamond Grinding ◽  
Electrical Discharge Dressing

Electrical discharge dressing and truing of diamond grinding wheel is a non-contact and non-traditional truing and dressing technology. In orde to help selecting optimized parameters under certain conditions such as peak current,etc.Fractal theory is application to set a electrical dischrge model .In this model,the fractal dimension ( ) is proportionately related to peak current( ) and pulse duration ( ).The actual dressing experiment was conducted to demonstrate the simulation model. There is a relationship between fractal dimension ( ) and the surface morphology of diamond grinding wheel.

Experimental Investigation on Bronze-Bonded CBN Formed Grinding Wheel by Means of Electro-Discharging Dressing

2016 ◽  
Vol 1136 ◽  
pp. 97-103
Author(s):  
Jian Wu Yu ◽  
Li Hua He ◽  
Hong Luo ◽  
Shao Hui Yin
Keyword(s):  
Electrical Discharge ◽  
High Efficiency ◽  
Pulse Current ◽  
Precision Machining ◽  
Grinding Wheel ◽  
Grinding Wheels ◽  
Abrasive Grains ◽  
Finishing Process ◽  
Discharge Parameters ◽  
Cbn Grinding Wheel

High-efficiency and precision machining of complicated components can be realized by using metal-bonded CBN grinding wheel. However, the difficulty in dressing those superabrasive grinding wheels is one of the main obstructions to popularize its application in industry. Different from the traditional methods, the aim of the paper is to investigate the electro-discharge dressing of bronze-bonded CBN formed grinding wheel. Based on the analysis of electrical discharge parameters and grinding performance, the results show that electro-discharge dressing of CBN formed grinding wheel is feasible. With the increase of pulse duration, pulse voltage and pulse current, the dressing efficiency is increasing, more abrasive grains are protruding, but surface topography of grinding wheel is worsen. Therefore, grinding tests show that, in order to get the dressing quality better and keep the dressing efficiency higher, the bigger electrical discharge parameters are chosen for rough dressing process and the smaller ones are chosen for finishing process.

Abrasive Grain Efficiency and Surface Roughness in Machining Magnesium Alloys by Newly Developed Cup-Type Diamond-Grinding-Wheels

2009 ◽  
Vol 620-622 ◽  
pp. 769-772
Author(s):  
Tien Dong Nguyen ◽  
Koji Matsumaru ◽  
Masakazu Takatsu ◽  
Kozo Ishizaki
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloys ◽  
Unit Length ◽  
Grinding Wheel ◽  
Light Metals ◽  
Grinding Wheels ◽  
Wheel Surface ◽  
Abrasive Grains ◽  
Diamond Grinding ◽  
Abrasive Grain

New cup-type diamond-grinding-wheels with hexagonal pattern have been developed. Grinding stone ratio, R is defined as the ratio between the hexagonal edge area containing abrasive grains and the total area of the wheel surface. In the present work, four kinds of hexagonal grinding wheels with different R (13 %, 19 %, 25 % and 36 %) and a conventional wheel (R: 100 %) were used to grind a light metals, which was represented by magnesium alloy AZ31B. Efficiency of abrasive grains and ground surface for machining a light metals were evaluated by calculating the number of abrasive grains which pass through a unit length of a sample surface for each grinding pass, Ng. The results show that surface roughness becomes smaller, i. e., smoother surfaces as Ng increases. Surfaces ground by the conventional wheel are rougher than those by using newly developed hexagonal grinding-wheels in spite of the larger Ng for the conventional wheel. Surface roughness data forms one curve in roughness vs. Ng graph for all hexagonal wheels, and forms another curve for the conventional grinding-wheel. The difference of two curves indicates that the number of effective working abrasive grains in hexagonal wheels is about 5 times higher than that of the conventional wheel. The similar results were obtained for machining sapphire according to our previous work. Hexagonal wheels show higher abrasive grain efficiency for machining not only hard-to-machine ceramics but also light metals such as magnesium alloys than conventional wheels.

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