Theoretical modeling and experiments of oxide layer contact stiffness for ultrasonic vibration–assisted electrolytic in-process dressing grinding

Based on the fundamental laws of electrochemistry and grinding, the theoretical models of oxide layer contact stiffness for the ultrasonic vibration–assisted electrolytic in-process dressing grinding system and the electrolytic in-process dressing grinding system are established, respectively. The numerical simulation analyses and experimental research are carried out for determining the reliability of the oxide layer contact stiffness models. Through numerical simulations, the affective trends of the grinding parameters, ultrasonic parameters, and electrolytic in-process dressing electrical parameters for oxide layer contact stiffness are obtained. The oxide layer contact stiffness decreases with either an increase in elastic deformation of the system or decrease in nominal grinding depth. The greater the nominal grinding depth, the more obvious the impacts on the oxide layer contact stiffness by the elastic deformation of the system. The oxide layer contact stiffness is inversely proportional to the ultrasonic amplitude, ultrasonic frequency, duty ratio, power supply voltage, and wheel speed, and it is directly proportional to the workpiece speed. With an increase in the oxide layer contact stiffness, the surface profile depth, surface roughness, and fractal dimension first decrease and then increase gradually. The research results are valuable for controlling oxide layer contact stiffness.