Mechanism of online dressing for micro-diamond grinding wheel during the ultrasound-aided electrolytic in-process dressing grinding

Abstract

A high-precision continuous dressing technology, namely ultrasound-aided electrolytic in-process dressing method, was proposed in this paper, aiming at overcoming the difficulty in continuous dressing for fine diamond wheel during the super mirror processing, such as optics and aeronautics. Firstly, the influence of high-frequency ultrasonic vibration on electrolysis was analyzed on the basis of the mechanism of electrolysis. Then, the compared tests between the common electrolytic in-process dressing grinding and the ultrasound-aided electrolytic in-process dressing grinding of the grinding wheel were employed to observe the effect of dressing and the state of abrasive particle. It was found experimentally that under the latter dressing, the better dressing effect could be gained, and the number of abrasive particle per unit area, the sharpness of abrasive and the average grain protrude height were improved; meanwhile, the distribution of grains become more uniform. In addition, compared with the former dressing, the average distance between grains was decreased, and the microscopic roughness of grinding wheel physiognomy was increased in the latter dressing. Finally, the grinding experiment was carried out to illustrate the advantages of the ultrasound-aided electrolytic in-process dressing grinding. The experimental results revealed that the removal rate and machining surface quality were increased compared with the common electrolytic in-process dressing grinding.