Skip to main content
SpringerLink
Log in

Metal-bonded diamond wheel dressing by using wire electrical discharge: principle and prototype machine design

  • Original Article
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Metal-bonded grinding wheels offer particular benefits for the grinding of difficult-to-machine materials. Such wheels have superior dimensional and thermal stability, and more quickly dissipate the grinding heat. To in-process dress the metal-bonded diamond wheels of complex contours with the high-precision, wire electrical discharge dressing (WEDD) was used to remove the excess metal material on the surface. A prototype CNC machine tool based on the WEDD method was developed. Some novel designs were proposed to improve the dressing precision and performance. An air spindle with sub-micron runout was used to clamp the metal-bonded diamond wheels, which aims to decrease the runout of the dressed wheels. A specially designed wire guide was used to limit and minimize the positional fluctuations of wire electrodes. To dress the complex shape grinding wheel, the C-axis was designed to adjust the angle of the wire guide relative to the wheel to be dressed, which avoided motion interference between them. In addition, a high-low-voltage power supply was developed. By using the high ignition voltage, it is possible to form the discharge channel under a large gap, and thus the grinding wheel with the large diamond grain of the size 75~90 μm could be dressed. WEDD of a metal-bonded diamond grinding wheel was performed on the developed prototype machine tool. The experimental results demonstrated that the developed prototype could realize the dressing of the grinding wheel with a runout of less than 2 μm. The grinding experiments showed that a better grinding surface with Ra less than 0.8 μm was obtained.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

Data availability

The datasets supporting the results of this article are included within the article.

References

  1. Suzuki H, Okada M, Yamagata Y et al (2012) Precision grinding of structured ceramic molds by diamond wheel trued with alloy metal. CIRP annals 61:283–286

    Article  Google Scholar 

  2. Rhoney BK, Shih AJ, Scattergood RO et al (2002) Wire electrical discharge machining of metal bond diamond wheels for ceramic grinding. Int J Mach Tools Manuf 42:1355–1362

    Article  Google Scholar 

  3. STUDER - The Art of Grinding, https://www.studer.com/en/cylindrical-grinding-machines/software-options/wiredressr/,2023. Accessed 2023.08.01

  4. Mingzheng LIU, Changhe LI, Zhang Y et al (2022) Analysis of grinding mechanics and improved grinding force model based on randomized grain geometric characteristics. Chin J Aeronaut 36(7):160–193

    Google Scholar 

  5. Zhang Y, Li C, Ji H et al (2017) Analysis of grinding mechanics and improved predictive force model based on material-removal and plastic-stacking mechanisms. Int J Mach Tool Manuf 122:81–97

    Article  Google Scholar 

  6. Gao T, Li C, Yang M et al (2021) Mechanics analysis and predictive force models for the single-diamond grain grinding of carbon fiber reinforced polymers using CNT nano-lubricant. J Mater Process Technol 290:116976

    Article  Google Scholar 

  7. Karpuschewski B, Lierse T, Kaul TR et al (2018) Kinematic process model and investigation of grain breakout for conditioning with CVD diamond dressing disks. CIRP J Manuf Sci Technol 22:21–29

    Article  Google Scholar 

  8. Chen B, Guo B, Zhao Q (2015) On-machine precision form truing of arc-shaped diamond wheels. J Mater Process Technol 223:65–74

    Article  ADS  Google Scholar 

  9. Zhang Z, Yao P, Zhang Z et al (2017) A novel technique for dressing metal-bonded diamond grinding wheel with abrasive waterjet and touch truing. Int J Adv Manuf Technol 93:3063–3073. https://doi.org/10.1007/s00170-017-0738-7

    Article  Google Scholar 

  10. Zhou C, Deng H, Chen G et al (2016) Numerical simulation of single-pulse laser ablation for dressing a bronze-bond diamond grinding wheel. Precis Eng 43:78–85. https://doi.org/10.1016/j.precisioneng.2015.06.012

    Article  Google Scholar 

  11. Walter C, Rabiey M, Warhanek M et al (2012) Dressing and truing of hybrid bonded CBN grinding tools using a short-pulsed fibre laser. CIRP Annals 61:279–282. https://doi.org/10.1016/j.cirp.2012.03.001

    Article  Google Scholar 

  12. Wang J, Zhang J, Feng P, Guo P (2018) Damage formation and suppression in rotary ultrasonic machining of hard and brittle materials: a critical review. Ceram Int 44:1227–1239. https://doi.org/10.1016/j.ceramint.2017.10.050

    Article  Google Scholar 

  13. Wang Z, Ren C, Chen G et al (2018) A comparative study on state of oxide layer in ELID grinding with tool-cathode and workpiece-cathode. Int J Adv Manuf Technol 94:1299–1307. https://doi.org/10.1007/s00170-017-0931-8

    Article  Google Scholar 

  14. Wang T, Wu C, Liu H et al (2020) On-machine electric discharge truing of small ball-end fine diamond grinding wheels. J Mater Process Technol 277:116472. https://doi.org/10.1016/j.jmatprotec.2019.116472

    Article  Google Scholar 

  15. Lee E-S (2000) Precision grinding of Mn-Zn ferrite with in-process electro-discharge dressing. Int J Adv Manuf Technol 16:314–321. https://doi.org/10.1007/s001700050163

    Article  Google Scholar 

  16. Gołąbczak M, Święcik R, Gołąbczak A et al (2021) Electrodischarge methods of shaping the cutting ability of superhard grinding wheels. Materials 14:6773. https://doi.org/10.3390/ma14226773

    Article  ADS  PubMed  PubMed Central  Google Scholar 

  17. Dai L, Chen G, Li M, Yuan S (2022) Experimental study on dressing concave trapezoidal diamond grinding wheel by electrical discharge grinding method. Diamond Relat Mater 128:109218. https://doi.org/10.1016/j.diamond.2022.109218

    Article  ADS  Google Scholar 

  18. Klink A (2010) Wire electro discharge trueing and dressing of fine grinding wheels. CIRP Annals 59:235–238. https://doi.org/10.1016/j.cirp.2010.03.076

    Article  Google Scholar 

  19. Sanchez JA, Pombo I, Cabanes I et al (2008) Electrical discharge truing of metal-bonded CBN wheels using single-point electrode. Int J Mach Tool Manuf 48:362–370. https://doi.org/10.1016/j.ijmachtools.2007.10.002

    Article  Google Scholar 

  20. Suzuki K, Uematsu T, Nakagawa T (1987) On-machine trueing/dressing of metal bond grinding wheels by electro-discharge machining. CIRP Annals 36:115–118. https://doi.org/10.1016/S0007-8506(07)62566-9

    Article  Google Scholar 

  21. Zahedi A, Khosravi J, Azarhoushang B (2021) Grinding efficiency and profile accuracy of diamond grinding wheels dressed with wire electrical discharge conditioning (WEDC). Int J Adv Manuf Technol 117:2163–2171. https://doi.org/10.1007/s00170-021-07114-2

    Article  Google Scholar 

  22. Weingärtner E, Jaumann S, Kuster F, Wegener K (2010) On-machine wire electrical discharge dressing (WEDD) of metal-bonded grinding wheels. Int J Adv Manuf Technol 49:1001–1007. https://doi.org/10.1007/s00170-009-2458-0

    Article  Google Scholar 

  23. Weingärtner E, Jaumann S, Kuster F, Boccadoro M (2010) Special wire guide for on-machine wire electrical discharge dressing of metal bonded grinding wheels. CIRP Annals 59:227–230. https://doi.org/10.1016/j.cirp.2010.03.010

    Article  Google Scholar 

  24. Chow HM, Yang L-D, Lin Y-C et al (2016) Processing characteristics exploration of metal based diamond wheel of WEDM dressing and truing. Int J Mater Sci Appl 5:290–296

    Google Scholar 

  25. Chow HM, Yang LD, Lin YC, Lin CL (2017) Exploration on wire discharge machining added powder for metal-based diamond grinding wheel on wire EDM dressing and truing of grinding tungsten carbide material. IOP Conf Ser: Mater Sci Eng 281:012022. https://doi.org/10.1088/1757-899X/281/1/012022

    Article  Google Scholar 

  26. Wang Y, Ma H, Jia J et al (2021) Machining of cylindrical parts by wire electrical discharge grinding using thin plate guide. Int J Adv Manuf Technol 113:1081–1096. https://doi.org/10.1007/s00170-020-06579-x

    Article  Google Scholar 

Download references

Funding

This research is supported by the Fundamental Research Program of Shanxi Province (20210302124209), National Nature Science Foundation of China (Grant No. 51605323), and Key Research and Development Program of Shanxi Province (Grant No. 201903D121048).

Author information

Authors and Affiliations

  1. College of Mechanical and Vehicle Engineering, Taiyuan University of Technology, Taiyuan, 030024, China

    Laijun Zhang, Xiuzhi Wang, Yanqing Wang, Huliang Ma, Zan Li & Jianyu Jia

  2. Shanxi Province Key Laboratory of Precise Machining, Taiyuan, 030024, China

    Laijun Zhang, Xiuzhi Wang, Yanqing Wang, Huliang Ma, Zan Li & Jianyu Jia

  3. Hai’ an Institute of Intelligent Equipment, SJTU, Nantong, 226600, China

    Xiuzhi Wang

Authors
  1. Laijun Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Xiuzhi Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yanqing Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Huliang Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zan Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jianyu Jia
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

The realization of this technology was mainly completed by Laijun Zhang. Xiuzhi Wang and Huliang Ma participated in the construction of the experimental device and the discussion of experimental results. Xiuzhi Wang, Jianyu Jia, and Zan Li participated in the discussion of the experimental results. Yanqing Wang proposed the main novel design ideas and provided guidance on research directions.

Corresponding authors

Correspondence to Xiuzhi Wang or Yanqing Wang.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

All authors have consented to publication.

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Xiuzhi Wang and Yanqing Wang are corresponding authors.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, L., Wang, X., Wang, Y. et al. Metal-bonded diamond wheel dressing by using wire electrical discharge: principle and prototype machine design. Int J Adv Manuf Technol 131, 2677–2690 (2024). https://doi.org/10.1007/s00170-023-12163-w

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-12163-w

Keywords

Search

Navigation