Study of α-Fe2O3 formation and its measurement in oxide films of wheel surface during ELID grinding process

2017 ◽  
Vol 31 (04) ◽  
pp. 1750025 ◽  
Author(s):  
Jicai Kuai ◽  
Dmitrii V. Ardashev ◽  
Huali Zhang
Keyword(s):  
Oxide Film ◽  
Spectrum Analysis ◽  
Ir Spectrum ◽  
Oxide Films ◽  
Grinding Wheel ◽  
Vibration Band ◽  
Wheel Surface ◽  
Characteristic Absorption Band ◽  
Forming Mechanism ◽  
Elid Grinding

This paper presents the study of forming mechanism of [Formula: see text]-Fe2O3 in oxide films on electrolytic in-process dressing (ELID) grinding wheel surface. To investigate the component content and the microtopography of oxide films, XRD, XPS, IR spectrum analysis, SEM, and TEM measurements are performed on ELID grinding wheels. In XRD test results, the characteristic absorption band of [Formula: see text]-Fe2O3 is found in the oxide film. XPS tests show that there is full of ferrous iron and oxygen element in the oxide film. Also, the characteristic spectral line of XPS is identical to the standard spectrum of [Formula: see text]-Fe2O3. Several vibration peaks (471, 1029, 1384, 1630, 3430) are observed by IR spectrum analysis. It can be easily seen by contrast with the standard photographs that the vibration peak of 1029 is of Fe-O vibration band in IR spectrum of [Formula: see text]-Fe2O3 powder. Therefore, these measurement results confirm the existence of [Formula: see text]-Fe2O3 in the oxide films, and explain the polishing effect of oxide films during ELID grinding. The fresh oxide film is porous and moisture rich. However, the oxide film after squeezing to dry is investigated by SEM imaging to present tortoiseshell cracks. Geometrically, [Formula: see text]-Fe2O3 appears to be nearly spherical with particle size around 5–50 nm. This indicates fine polishing improvement by oxide films, and is identified as the mechanism responsible for excellent surface quality by ELID grinding.

Forming Mechanism of Composite Abrasive Grains in Oxide Film on ELID Wheel and its Microstructure

2016 ◽  
Vol 709 ◽  
pp. 77-81 ◽  
Author(s):  
Ji Cai Kuai ◽  
Cheng Ran Jiang ◽  
Jiang Wei Wang
Keyword(s):  
Oxide Film ◽  
Grinding Wheel ◽  
Compound Structure ◽  
Wheel Surface ◽  
Forming Mechanism ◽  
Elid Grinding ◽  
Abrasive Grains ◽  
Shaped Crack

In this paper we analyze the forming mechanism of composite abrasive grains in oxide film on ELID grinding wheel surface, By using composition information and by taking advantage of microscale structure, we have investigated that abrasive grains surface is covered by a layer of oxide film and the fresh oxide film is loose and porous like turtle shaped crack when crushed and dried. The elements of oxide film consist of α-Fe2O3 with sphere grain of 5-50nm. This phenomena is demonstrated that the composite abrasive grains in oxide film is a compound structure which is centered by abrasive grains, with α-Fe2O3,Fe (OH)3 surrounded.

Forming Mechanism of α-Fe2O3 in the Oxide Films on Iron-Bonded Diamond Wheel Surface by ELID Grinding

2016 ◽  
Vol 723 ◽  
pp. 434-438 ◽  
Author(s):  
Hua Li Zhang ◽  
Ji Cai Kuai
Keyword(s):  
Photoelectron Spectroscopy ◽  
Oxide Films ◽  
Diamond Wheel ◽  
Grinding Wheel ◽  
X Ray Diffraction ◽  
Wheel Surface ◽  
X Ray ◽  
Forming Mechanism ◽  
Elid Grinding ◽  
Standard Spectrum

The formation mechanism of α-Fe2O3 on iron-bonded diamond wheel surface by ELID grinding is presented here. X-ray diffraction (XRD) and X-ray photoelectron spectroscopy (XPS) techniques were used to analyze the compositions of the oxide films. X-ray diffraction analysis demonstrated the existence of the diffraction peak of α-Fe2O3, which was observed in ELID grinding iron-bonded diamond wheel surface. To illustrate the correctness of our theory, X-ray photoelectron spectroscopy analysis was also performed. Results reveal that the characteristic spectrum of oxide film on ELID wheel has coincidence with the standard spectrum of Fe2p in α-Fe2O3. These results suggest the existence of α-Fe2O3 in oxide films on the grinding wheel surface. The potentiality that α-Fe2O3 can bring polishing effect to ELID grinding process has also been discussed. It helps understand how ELID grinding can achieve excellent surface finish for the workpiece.

Experimental study on the characteristic and function of oxide film formed on grinding wheel in ELID precision grinding

2019 ◽  
Vol 72 (5) ◽  
pp. 549-555
Author(s):  
Jia-Bo Zhang ◽  
Yang Yang ◽  
Xiao-Hui Zhang ◽  
Jia-Liang Guan ◽  
Li-Yan Zheng ◽  
...  
Keyword(s):  
Oxide Film ◽  
Formation Rate ◽  
Combination Method ◽  
Grinding Wheel ◽  
Precision Grinding ◽  
Content Type ◽  
Elid Grinding ◽  
Grinding Fluid ◽  
Film Forming ◽  
And Function

Purpose The purpose of this study is to investigate the characteristic and function of oxide film formed on grinding wheel in electrolytic in-process dressing (ELID) precision grinding and improve the quality of ELID grinding. Design/methodology/approach Dynamic film forming experiments were carried out with a simulation device close to the actual processing conditions. Then, the ELID grinding experiments of bearing rings were performed using grinding wheels with good film forming effect. The experiment was designed by quadratic regression general rotation combination method. The influence of grinding depth, electrolytic voltage, duty cycle and grinding wheel linear speed on grinding effect is analyzed. Findings A mathematical model for the formation rate of oxide film was established. The experiments show that the composition of grinding wheel and grinding fluid, as well as the electrical parameters, influence the film forming effect. Thus, the oxide film plays an important role in ELID grinding. Originality/value This study provides a reference for the design and selection of grinding wheel and grinding fluid and the setting of process parameters in ELID grinding.

Adhesion Model and Shedding Limit's Identification of the Oxide Film on the Surface of ELID Grinding Wheel

2014 ◽  
Vol 900 ◽  
pp. 557-560 ◽  
Author(s):  
Ji Cai Kuai
Keyword(s):  
Oxide Film ◽  
Adhesion Strength ◽  
Grinding Force ◽  
Adhesion Property ◽  
Cemented Carbide ◽  
Grinding Wheel ◽  
Strength Model ◽  
Elid Grinding ◽  
Adhesion Model

The adhesion property of oxide film has great effects on the grinding quality and efficiency of ELID grinding. In this paper, adhesion strength model of oxide film is established, ELID grinding is conducted to nanometric cemented carbide and ordinary cemented carbide, ELID grinding force is measured, adhesive stress is calculated and the correctness of adhesion model is verified. The results show that the adhesion strength of oxide film is relatively greater, the transition from γ-Fe2O3to α-Fe2O3in the oxide film is relatively fuller and the polishing performance is relatively better while the grinding depth is smaller; with the deepening of grinding, the adhesion strength of oxide film reduces, the composition of the oxide film that transforms into α-Fe2O3is less and the polishing ability reduces. The adhesion model of oxide film well reflects the adhesion property of oxide film, and the application of this model can represent the distribution, shedding and updating of the oxide film on the surface of grinding wheel.

Friction Coefficient of Nano-Ceramic Polished by Oxide Film on ELID Grinding Wheel

2013 ◽  
Vol 669 ◽  
pp. 91-94 ◽  
Author(s):  
Ji Cai Kuai
Keyword(s):  
Friction Coefficient ◽  
Oxide Film ◽  
Normal Force ◽  
Tangential Force ◽  
Grinding Wheel ◽  
Nano Materials ◽  
Dynamic Changes ◽  
Bonding Agents ◽  
Elid Grinding ◽  
Feeding Speed

The dynamic changes of the friction properties of the oxide film are characterized by the dynamic changes of the ELID grinding force. The tangential force and normal force are used to represent the friction coefficient in order to obtain the accurate real-time friction coefficient of oxide film. Therefore, the friction coefficient of various grinding wheels with different bonding agents, various grinding parameters, various grinding materials (nano- Al2O3 ceramic, nano ZrO2 ceramic and ordinary ZrO2 ceramic), and ELID grinding and ordinary grinding can be further studied. The results show that: the friction coefficient of the oxide film on the bronze-based grinding wheel is greater than that composed by iron; the friction coefficient of the oxide film decreases with the increase in grinding depth and feeding speed; the friction coefficient of the oxide film and nano-materials is smaller than that of the oxide film and ordinary materials; the transformation from γ-Fe2O3 to α-Fe2O3 in oxide film and the elastic deformation of the oxide film caused by the high-temperature of grinding may make the friction coefficient of ELID grinding greater than that of ordinary grinding, so the oxide film contains better property of friction and polishing. Therefore, excellent surface quality is easier to be obtained by it compared with the ordinary grinding technology.

Discovery of α-Fe2O3 in the Oxide Film on ELID Grinding Wheel

2014 ◽  
Vol 1061-1062 ◽  
pp. 446-449 ◽  
Author(s):  
Ji Cai Kuai
Keyword(s):  
Oxide Film ◽  
Experimental Verification ◽  
Theoretical Study ◽  
Electrochemical Process ◽  
Grinding Wheel ◽  
Transformation Mechanism ◽  
X Ray ◽  
Elid Grinding

This paper conducted a theoretical study on the generation and transformation mechanism of α-Fe2O3in the oxide film and an experimental verification of the presence of it. Firstly, the electrochemical process of the generation and transformation of α-Fe2O3in the oxide film was analyzed, followed by the measurement of the content of it in the oxide film using X-ray diffractometer.

Manufacturing Technology of α-Fe Bonded Grinding Wheel Free Abrasive

2018 ◽  
Vol 780 ◽  
pp. 111-115 ◽  
Author(s):  
Ji Cai Kuai ◽  
Dmitrii V. Ardashev ◽  
Jia Qi Zhang ◽  
Hua Li Zhang
Keyword(s):  
Oxide Film ◽  
High Surface ◽  
Grinding Wheel ◽  
Mirror Surface ◽  
Precision Grinding ◽  
Abrasive Particles ◽  
Elid Grinding ◽  
Abrasive Grain ◽  
Ultra Precision ◽  
Free Abrasive

ELID ultra-precision grinding mirror surface can achieve nanometer precision. However, after the grinding wheel passivates the abrasive particles in electrolysis, it is easy to scratch the ultra-precision ELID grinding surface into the grinding process. In order to solve this problem, a non-abrasive grain α-Fe bonded grinding wheel is propose, which contains no abrasive particles. After electrolysis, oxide film is formed on the surface of the wheel. In ultra-precision ELID grinding, there is no abrasive particles involved, only the polishing effect of oxide film. There is no need to worry about the scratching of exfoliated abrasive particles that have been machined on ultra-precision ELID surfaces. Thus achieving extremely high surface accuracy.

Modeling of Thickness of the Oxide Film in ELID Grinding

2010 ◽  
Vol 135 ◽  
pp. 376-381 ◽  
Author(s):  
Hua Li Zhang ◽  
Ji Cai Kuai ◽  
Fei Hu Zhang
Keyword(s):  
Oxide Film ◽  
Theoretical Calculation ◽  
Simulation Analysis ◽  
Oxide Films ◽  
Calculation Model ◽  
Experimental Results ◽  
Elid Grinding ◽  
On Line ◽  
Simulation Results ◽  
Good Agreement

The properties of oxide films are very important for improving the mass of ELID grinding surface. In this paper, a novel calculation model of thickness of oxide films was proposed; the theoretical calculation and simulation analysis were developed, and were compared with the corresponding experimental results. The results proved that the theoretical calculation and simulation results of the thickness of the oxide films had good agreement with the experimental results. This model could predict precisely the change of thickness of oxide film, the instinct of non-linear electrolysis was explained from a novel aspect of ability of pulsed electrolysis. This model could be used in the on-line control of electrolytic state during practical ELID grinding process.

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