ENHANCING PRECISION ENGINEERING THROUGH ON-SITE ELECTRIC SPARK CONDITIONING OF METAL-BONDED DIAMOND GRINDING WHEELS

Abstract

Metal-bonded diamond grinding wheels are renowned for their exceptional grinding capabilities, including high efficiency, low grinding force, and minimal temperature rise, making them indispensable for precision and ultra-precision grinding of hard and brittle materials. However, these wheels exhibit limitations such as poor self-sharpness, susceptibility to clogging, and issues related to eccentricityinduced vibrations, which significantly impact grinding stability and surface quality. Furthermore, the grinding wheel's shape deterioration during the machining of hard materials, such as silicon carbide ceramics, poses a substantial challenge to workpiece precision. Therefore, the development of efficient and high-quality finishing techniques for metal-bonded diamond grinding wheels is crucial for advancing hard and brittle material grinding processes. This study explores the application of electric spark shaping as a novel and effective method for in-situ shaping and sharpening of metal-bonded diamond grinding wheels. The technique offers several advantages, including precise control of the grinding geometry, ease of operation, compatibility with grinding wheels featuring conductive bonding agents, minimal grinding force generation, and suitability for dressing processes involving small-diameter and ultra-thin wheels. Electric spark shaping is a cost-effective and readily implementable method with minimal process parameters, facilitating easy adjustments to meet specific requirements. Consequently, it emerges as the optimal choice for dressing metal-bonded diamond grinding wheels