Papers by Keyword: ELID (Electrolytic In-Process Dressing)

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Authors: Seok Woo Lee, Hon Jong Choi, Hyun Woo Lee, Jae Young Choi, Hae Do Jeong
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Authors: Cheng Zu Ren, X.J. Guo, Li Wei Yuan
Abstract: In the paper, the Molecular Dynamics (MD) simulation model and the Finite Element (FE) analysis model were combined together to study the mechanism of the Electrolytic In-process Dressing (ELID) grinding. A 3-D MD simulation model for grinding monocrystalline silicon was established to acquire grinding force and its change laws, and an interpolation multinomial of grinding force was established on the basis of MD simulation result. A FE model for abrasives and the passivation film was established to calculate displacement of abrasives in the passivation film. The grinding force and abrasives displacement were iterated between MD simulation model and FE analysis model to obtain the displacement variation of the abrasives in the passivation film. The simulation result shows that, the uniform height of the abrasives in the contour of the grinding wheel is improved owing to the existence of passivation film in ELID grinding, it is related to the thickness of the passivation film, and processing quality in ELID grinding could be enhanced through controlling of thickness of the passivation film.
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Authors: Hitoshi Ohmori, Shao Hui Yin, Wei Min Lin, Yoshihiro Uehara, Shinya MORITA, Muneaki Asami, M. Ohmori
Abstract: Metal bonded diamond grinding wheels are widely used in the grinding process, especial in ELID grinding. However, truing is difficult owing to the high toughness of metal bond materials and high hardness of diamond abrasives. To realize high precision and high-efficiency truing, we propose a new micro-truing method consisting of electro-discharge truing and electrolysis-assisted mechanical truing in this paper. The process principle and fundamental experimental results are introduced, and the truing performance is discussed. Research results show that the proposed new method is effective for truing metal bonded diamond grinding wheels.
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Authors: Zhen Tao Shang, Han Huang, S.Q. Wang, Xiao Min Sheng, Hai Qing Mi
Abstract: Electrolytic In-process Dressing (ELID) has been applied in high speed grinding of partially stabilized zirconia. Using a developed electrode system, the ELID effect on a bronze bond diamond wheel was significant. This resulted in a decrease in grinding force, and thus improved the ground surface quality. The improvement of grinding performance was attributed to the good maintenance of wheel sharpness by ELID dressing.
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Authors: Qing Liang Zhao, Jun Yun Chen, Jun Yao
Abstract: In this paper, a copper-resin bonded diamond wheel was applied to machine the optical glass on a precision grinder. The process of truing and pre-dressing with ELID (electrolytic in-process dressing) were first carried out for the grinding wheels, then the ELID assisted grinding experiments were conducted with the special fine and coarse grained diamond wheels. The experimental results show that the fine and coarse grained wheels can all generated the smooth surface with the surface roughness in nanometer scale and the coarse grained diamond wheel correlates to the slightly more surface damage than the fine grained diamond wheel, which also proves that the high efficient grinding of the optical glass with a good surface quality can be realized with the coarse grained copper-resin wheel on a precision grinder and the grinding wheels were all well conditioned with the conditioning method presented in this paper.
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Authors: Qing Liang Zhao, Ekkard Brinksmeier, Otmann Riemer, Kai Rickens
Abstract: In order to realize ductile machining of optical glasses using mono-layer nickel electroplated coarse-grained diamond grinding wheel, a novel conditioning technique features using a copper bonded diamond grinding wheels of 15m grain size dressed by ELID (electrolytic inprocess dressing) to condition the 46m grain sized diamond wheel has been developed. During the conditioning process, a force transducer was used to monitor the conditioning force, a coaxial optical distance measurement system was used to in-situ monitor the modified wheel surface status. White-light interferometry (WLI), scanning electron microscopy (SEM) and atomic force microscopy (AFM) were used to characterize the conditioned wheel surface status as well as the ground optical glass surface topography correspondingly. The experimental result indicates that a minimized wheel radial run-out error of less than 2μm as well as the top-flattened diamond grains of constant wheel peripheral envelop profile were generated on a 5-axis ultra-precision machine tool. The grinding experiment proved that the well conditioned 46μm coarse-grained diamond wheel can be used in realizing the ductile grinding of optical glass BK7, which indicates that the newly developed conditioning technique is feasible and applicable to introduce the coarse-grained diamond wheels into precision machining of brittle and hard-to-machine materials.
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Authors: Cheng Zu Ren, J.M. Che, Tai Yong Wang, W.D. Jin, Xin Min Jin
Abstract: The state of the passivating film is a key factor affecting ELID grinding. In the paper the state of the passivating film on the grinding wheel surface was characterized by the loop current, the strategies actively controlling the film state, discontinuous in-process electrolyzing and intermittent grinding were put forward, and the ELID grinding tests under the conditions of actively controlling of the film state and the traditional dynamic balance of the film state were respectively performed and contrasted with each other. It is indicated that by real-time monitoring of the film state with the loop current, the film state variation could be controlled to a narrow scope with the strategies of discontinuous in-process electrolyzing and intermittent grinding, as a result the ELID grinding kept at a fine quality and a high efficiency.
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Authors: Kazutoshi Katahira, Hitoshi Ohmori
Abstract: The present paper describes the highly efficient and precise ELID grinding method and presents a discussion on the ELID grinding process and the grinding characteristics of several kinds of ceramic materials. The following conclusions are obtained; (1) Good ground surface roughness and accuracy are achieved using the #4000 metal-bonded grinding wheel in through-feed centerless grinding for ZrO2 optical fiber ferrules. (2) Efficient and precise grinding of spherical lens molds with cup wheels using the ELID CG-grinding process was proposed and tested in the present study. (3) The ELID grinding method can be used to fabricate machined surfaces exhibiting desirable characteristics for hard AlN ceramics. The ELID ground AlN demonstrated a surface hardness and sliding characteristics that were superior to those of the polished series. These advantages may be attributable to the diffusion phenomenon of the oxygen element produced by the ELID grinding.
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Authors: Ji Cai Kuai
Abstract: The electrolytic in-process dressing (ELID) technology was combined with ultrasonic honing technology and ELID-ultrasonic honing system was proposed. And the electrolysis parameters, ultrasound parameters, honing parameters reasonable were matched for ELID- ultrasonic honing system and the honing processing experiments were carried out. Studies have shown that parameters in ELID-ultrasonic honing system are independent without disturbing each other. Compared to traditional honing and ultrasonic honing, ELID-ultrasonic honing system has a significant advantage in machining accuracy, surface roughness, processing efficiency and so on. The feasibility of ELID- ultrasonic honing system is validated, which provided a new compound method of honing for ultra-precision honing machining.
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Authors: Fei Hu Zhang, J.C. Gui, Yi Zhi Liu, Hua Li Zhang
Abstract: Nano cemented carbide is a new style cutter material. Because its grain size is very small, it is superior to common cemented carbide in properties, such as high hardness, fracture toughness, flexural strength and higher abrasion resistance. As a cutter material, nano cemented carbide has wide use. In this paper, nano cemented carbide tool was ground with ELID technology, and the cutting properties of nano cemented carbide were studied, and the difference in cutting properties among the ultra-fine grain, common cemented carbide and nano cemented carbide was analyzed under the same condition. Results imply that the ground surface roughness of nano cemented carbide is obviously lower than that of common cemented carbide, and the tool life of nano cemented carbide is 5-7 times longer than that of common cemented carbide at low cutting speed.
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