In-Process Electrical Dressing of Metal-Bonded Diamond Grinding Wheels
A new development of hybrid in-process electrical dressing of metal-bonded diamond grinding wheels is proposed in this paper. The electrical dressing method is used for overcoming the limitations of the conventional dressing methods available in relation to a super-abrasive wheel because of the hardness of its abrasive grains and the durability of its bonding material. The proposed hybrid in-process electrical dressing method consists of electro-discharge and electro-chemical processes and is implemented with twin copper electrodes and alternating power supplies. The results show that with properly maintained process conditions, a better surface finish is produced by the proposed method compared with traditional rotating SiC wheel dressing.
Processing Characteristics Exploration of Metal Based Diamond Wheel of WEDM Dressing and Truing
This study aims to conduct experiments to explore metal based diamond wheel dressing and truing using developed wire electrical discharge (WEDM). The experimental outputs were analyzed to evaluate the effects of machining parameters on machining removal rate (MRR) and abrasive protrusion during dressing and truing caused by WEDM. During experiments, the wear and compensation issues could be overcome induced by the traditional EDM to improve the efficiency and precision as the WEDM was adopted. The experimental results showed as expected that the wire discharge grinding wheel dressing will lead the processing base not offset. In Taguchi experiment the maximum contribution was current and pulse time, large diameter grinding wheel to remove the highest rate of 11.78 mm3/min, while maximum protrusion amount only 33.12 μm, can reach the theoretical maximum protrusion amount.
Direct adaptive control of plunge grinding process using acoustic emission (AE) sensor
Modelling and adaptive control of plunge grinding operations using Acoustic Emission (AE) sensor are presented. The AE sensor is mounted on the grinding wheel spindle center, and the signals are transmitted to the receiver using a wireless transmission media. The root mean square (RMS) level of the AE signals are calibrated against major grinding parameters such as specific material removal rate, specific material removal, grinding wheel and workpiece diamters and wheel dressing conditions. The plunge grinding process is either planned a priori or adaptively controlled to achieve a desired surface finish quality using the experimentally calibrated empirical models. This adaptive control system is interfaced to a commercial CNC cylindrical grinding machine tool, and its effectiveness is demonstrated with grinding tests.