Electrochemical grinding of ceramic form tooling

Abstract This research investigates the process of electrochemical grinding (ECG) when used to machine metal-bonded diamond composite wheels. These wheels are used as form tools to grind ceramics. The wheels have to be machined to form and to tight tolerances, in good time. The most common of the metal-bonded types are those with mild steel and bronze bonds. To machine these wheels using ECG, direct nickel-plated diamond composite form tools are used. In order to achieve the required tight tolerances and minimum production time, the process has to be optimised. The optimisation criterion was based on the tolerances of the machined form, on the surface topography of both the metal bond wheel segments (as the workpiece) and the plated form tool and also on the grinding time observed. Operational parameters such as feed rate, electrolyte flow and current density, were investigated. The optimum operating conditions were evaluated. A comparison with conventional grinding methods was made also.