Electrolytic in-process dressing grinding of arc groove with workpiece swing

• Published in: International journal of advanced manufacturing technology Vol. 120; no. 3-4; pp. 1929 - 1947
• Main Authors: Liu, Zedong, Ren, Chengzu, Zhao, Kun, Chen, Guang, He, Chunlei, Liu, Xiao
• Format: Journal Article
• Language: English
• Published: London Springer London 01.05.2022; Springer Nature B.V
• Subjects: Accuracy; Angular velocity; Arc cutting; CAE) and Design; Computer-Aided Engineering (CAD; Electrolytic in process dressing; Engineering; Grinding wheels; Grooves; Industrial and Production Engineering; Mechanical Engineering; Media Management; Original Article; Wear mechanisms; Wheel dressing; Workpieces; Arc groove; Workpiece swing; Profile shape; Electrolytic in-process dressing grinding; Shape error
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-022-08904-y

This paper proposes an electrolytic in-process dressing (ELID) grinding method with workpiece swing to solve the problem associated with the duplication of profile errors between the wheel and groove in the cut-in ELID grinding process. In this work, the arc trajectory feed and ELID grinding were combined to improve the profile accuracy of the arc groove. Furthermore, subject to the new process conditions, a trajectory equation was established by analyzing the movement of the wheel relative to the groove surface, and a trajectory simulation was conducted according to the trajectory equation. Based on the comparative experiment of ELID grinding with workpiece swing and cut-in ELID grinding, the profile shape and shape error of the groove surface were compared and analyzed at different process conditions. The experimental results showed that in cut-in ELID grinding, the shape error ( Pt ) was 1.0551 μm. In ELID grinding with workpiece swing, Pt increased from 0.4316 to 0.7887 μm as the swing amplitude increased from 10° to 30°. As the swing angular velocity increased from 5 to 15°/s, Pt decreased from 0.9701 to 0.4789 μm. Under the new process conditions, both the wheel surface and groove surface demonstrated a uniform wear mechanism along the groove profile direction. The profile accuracy of the groove surface could be improved, and the profile accuracy of the wheel surface was ensured. The proposed method offers considerable advantages pertaining to the improvement of the profile accuracy of the arc groove.