On-machine electric discharge truing of small ball-end fine diamond grinding wheels

Abstract

Abstract Small ball-end metal bonded fine diamond wheel (SBFDW) is mainly applied to finishing complex components with small curved surfaces. Hence, it needs to investigate the influence of electrical parameters on the on-machine electric discharge truing of the SBFDW. Material removal characteristics in SBFDW truing are studied to analyze the relationship between the electrical parameters and profile accuracy. Profile accuracy and surface characteristics of the SBFDW and surface quality of the ground workpiece are experimentally investigated to evaluate the truing quality. The relationship between the electrical parameters and profile accuracy is established, based on which sensitivity analysis is used to reveal the influence degree of different factors. Among these factors, the open voltage has the most significant influence on the profile accuracy. Single pulse discharge energy will affect the surface topography of the SBFDW and further affect the grinding quality. When the energy is high enough, burns occur, recast layer covers the grinding wheel, and graphitization of diamond grits occurs. The surface roughness value of workpiece and grinding force increase with the increase of the truing energy. Then, a truing strategy combining low energy truing and high energy truing is proposed for truing the SBFDW. The trued SBFDW is proved to be suitable for grinding the complex components.