Efficient and stable grinding of ceramics by electrolytic in-process dressing (ELID)

Abstract

In the manufacture of structural ceramic components, it has been well documented that the grinding costs can be as high as 90% of the total cost. Grinding costs can be reduced by maximizing the material removal rates (MRR). A novel grinding technology that incorporates in-process dressing of metal-bonded superabrasive wheels, known as electrolytic in-process dressing (ELID) has been developed. This technology provides dressing to metal-bonded wheels during the grinding process for continuous protrudent abrasive from super-abrasive wheels. High MRR reciprocating grinding operation was performed on silicon nitride materials. Compared with conventional grinding, a significant reduction in grinding force was noted when ELID grinding was performed. The full effect of the ELID process, i.e., low and stable grinding force, was observed only after the grinding was performed for a certain period of time. The investigations have shown that low and stable grinding force can be obtained from the very beginning of the grinding process of ELID grinding combined with modified ELID dressing is performed. The results of this research will be addressed in this paper.