Analysis of Factors Effecting Profile Accuracy of Metal-Bonded Ball-Headed Diamond Wheel in Electrical Discharge Dressing Process

Abstract:

Metal-bonded ball-headed diamond wheel with small diameter has been widely used in the ultra-precision grinding of optical parts, especially in the parts with complex surface. In-position precise dressing technique of ball-headed diamond wheel is the key technology to improve grinding precision. The effect of mechanical errors on the profile accuracy of wheel dressing were theoretically analyzed firstly. Afterwards a ball-headed diamond wheel dressing equipment based on electrical discharge principle has been designed and built. Orthogonal experiments have been carried out on the dressing equipment, and the dressing quality of wheels under different dressing electrical parameters were analyzed in terms of wheel profile accuracy and wheel surface micro-topography. The influence of dressing electrical parameters on the dressing quality were investigated and the best electrical parameter combination was obtained. Experimental result showed that the wheel profile accuracy can reach upward 0.8μm after dressing, and the protrusion heights of diamond grain were uniformity and the protrusion effect was better than without dressing.

• Periodical: Materials Science Forum (Volumes 626-627)
• Pages: 41-46
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.626-627.41
• Online since: August 2009
• Authors: M.J. Chen, Ziang Li, Ying Chun Liang, Z. Fang
• Keywords: Ball-Headed with Small Diameter, Dressing Electrical Parameter, Dressing Quality, Electrical Discharge Dressing, Metal-Bonded Diamond Wheel

References

[1] S.H. Yin and S. Morita. H. Ohmori: ELID precision grinding of large special Schmidt plate for fibre multi-object spectrograph for 8. 2 m Subaru telescope. International Journal of Machine Tools & Manufacture. Vol. 45 (2005), pp.1598-1604.

DOI: 10.1016/j.ijmachtools.2005.02.010

[2] Y. Aono, M. Negishi and J. takano: Development of large aperture spherical lens with glass molding. In Advanced Optical Manufacturing and Testing Technology 2000, Proceedings of SPIE. Vol. 4231, pp.16-19.

DOI: 10.1117/12.402759

[3] M.J. Chen, Q.L. Zhao and S. Dong: Development of an ultra-precision grinding system for machining optical aspheric components with a large depth diameter ratio. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. Vol. 216 (2002).

DOI: 10.1243/095440502320783404

[4] J.M. Derkx and A.M. Hoogstrate: Forum crush dressing of diamond grinding wheels. Manufacturing Technology. Vol. 57 (2008), pp.348-352.

DOI: 10.1016/j.cirp.2008.03.065

[5] T. Saleh and M. Sazedur Rahman, H.S. Lim: Development and performance evaluation of an ultra precision ELID grinding machine. Journal of Materials Processing Technology. 192-193 (2007), pp.287-291.

DOI: 10.1016/j.jmatprotec.2007.04.034

[6] A. Hosokawa, T. Ueda and T. Yunoki: Laser Dressing of Metal Bonded Diamond Wheel. CIRP Annals - Manufacturing Technology. Vol. 55 (2006), pp.329-332.

DOI: 10.1016/s0007-8506(07)60428-4

[7] K. Suzuki and T. Uematsu: On-truing/dressing of metal bond grinding wheels by electro discharge machining. Ann. CIRP Manufacture Technology. Vol. 36 (1997), pp.115-118.

DOI: 10.1016/s0007-8506(07)62566-9

[8] P. Matoorian, S. Sulaiman and M.M.H.M. Ahmad: An experimental study for optimization of electrical discharge turning (EDT) process. Journal of Materials Processing Technology. 204 (2008), pp.350-356.

DOI: 10.1016/j.jmatprotec.2007.11.058

[9] J. Xie and J. Tamaki: An experimental study on discharge mediums used for electro-contact discharge dressing of metal-bonded diamond grinding wheel. Journal of Materials Processing Technology. 208 (2008), pp.239-244.

DOI: 10.1016/j.jmatprotec.2007.12.115