Experimental study of wheel wear in electrolytic in-process dressing and grinding

Profile accuracy of components ground with ultra-precision machine tools is primarily dependent on wheel wear. Quantitative analysis of wheel wear is therefore an important aspect for precision grinding with electrolytic in-process dressing (ELID). In this paper, wheel wear is measured from ELID grinding experiments with different dressing and machining parameters. The grinding forces and dressing current characteristics of the experiments are also compared. Based on the results, a benchmark function is defined for wheel wear rate. A relation for identifying insufficient dressing from sufficient dressing for particular machining conditions is also identified. It is found that insufficient dressing produces pitting and/or arcing on the wheel surface, and wheel wear can be linearly correlated to ELID grinding conditions when the wheels are sufficiently dressed.

[1]  Zhijian Pei,et al.  ELID grinding of silicon wafers: A literature review , 2007 .

[2]  Toshio Sata,et al.  Study on Wear of Grinding Wheels: 1—Bond Fracture in Grinding Wheels , 1963 .

[3]  D. Hutton,et al.  Acoustic Emission Monitoring of Tool Wear in End-Milling Using Time-Domain Averaging , 1999 .

[4]  Mahmudur Rahman,et al.  Efficient dressing of the wheel in ELID grinding by controllable voltage with force feed back , 2010 .

[5]  A. Senthil Kumar,et al.  A fundamental study on the mechanism of electrolytic in-process dressing (ELID) grinding , 2002 .

[6]  Masahiro Anzai,et al.  Development of Large Ultraprecision Mirror Surface Grinding System with Elid , 2002 .

[7]  T. Bifano,et al.  Fixed-Load Electrolytic Dressing With Bronze Bonded Grinding Wheels , 1999 .

[8]  Xiao-Hua Wang,et al.  Simulation and Analysis of Rigid/Foil Electrolytic In-Process Dressing (ELID) Systems for Grinding , 2004 .

[9]  Ioan D. Marinescu,et al.  Grinding of Ceramic Coatings with Cast Iron Bond Diamond Wheels. A Comparative Study: ELID and Rotary Dresser , 2001 .

[10]  J. A. McGeough,et al.  Principles of electrochemical machining , 1974 .

[11]  Fritz Klocke,et al.  Electrochemical oxidation analysis for dressing bronze-bonded diamond grinding wheels , 2007, Prod. Eng..

[12]  Hong Chen,et al.  Anodic metal matrix removal rate in electrolytic in-process dressing I: Two-dimensional modeling , 2000 .

[13]  Wei Li,et al.  Small-hole machining of ceramic material with electrolytic interval-dressing (ELID-II) grinding , 2000 .

[14]  Mahmudur Rahman,et al.  Development of an on-machine profile measurement system in ELID grinding for machining aspheric surface with software compensation , 2008 .

[15]  Weimin Lin,et al.  ELID precision grinding of large special Schmidt plate for fibre multi-object spectrograph for 8.2 m Subaru telescope , 2005 .

[16]  A. Senthil Kumar,et al.  Nano finish grinding of brittle materials using electrolytic in-process dressing (ELID) technique , 2003 .

[17]  Tanveer Saleh,et al.  Development and performance evaluation of an ultra precision ELID grinding machine , 2007 .

[18]  B. Ratnakumar,et al.  Studies on niobium triselenide cathode material for lithium rechargeable cells , 1988 .

[19]  N. Cook,et al.  The Wear of Grinding Wheels: Part 1—Attritious Wear , 1971 .

[20]  B. P. Bandyopadhyay,et al.  Efficient and stable grinding of ceramics by electrolytic in-process dressing (ELID) , 1997 .

[21]  A. Senthil Kumar,et al.  Characterization of ELID grinding process for machining silicon wafers , 2008 .

[23]  A. Senthil Kumar,et al.  A study on wear mechanism and wear reduction strategies in grinding wheels used for ELID grinding , 2003 .

[24]  Ioan D. Marinescu,et al.  Observations on Polishing and Ultraprecision Machining of Semiconductor Substrate Materials , 1995 .

[25]  Fathima Patham,et al.  Design and development of a novel computer controlled power device for electrical-assisted optical grinding , 2007, Optifab.

[26]  W. Graham,et al.  Fracture wear of grinding wheels , 1978 .

[27]  Ioan D. Marinescu,et al.  Investigation of pre-dressing time for ELID grinding technique , 2004 .

[28]  Mark Versteyhe,et al.  A Nanometre-precision, Ultra-stiff Plezostepper Stage for ELID-grinding , 2003 .

[29]  T. Nakagawa,et al.  Mirror Surface Grinding of Silicon Wafers with Electrolytic In-Process Dressing , 1990 .

[30]  K Katahira,et al.  ELID grinding and tribological characteristics of TiAlN film , 2002 .

[31]  Ichiro Inasaki,et al.  Initiatives of Precision Engineering at the Beginning of a Millennium , 2002 .

[32]  G. T. Burstein,et al.  The Current‐Time Relationship during Anodic Oxide Film Growth under High Electric Field , 1989 .

[33]  Masayoshi Mizutani,et al.  Functionalization of stainless steel surface through mirror-quality finish grinding , 2008 .

[34]  A. Senthil Kumar,et al.  Performance evaluation of a newly developed electrolytic system for stable thinning of silicon wafers , 2006 .

[35]  D. J. Stephenson,et al.  A study on ELID ultra precision grinding of optical glass with acoustic emission , 2006 .