Ultra-precision grinding machine design and application in grinding the thin-walled complex component with small ball-end diamond wheel

  • Tingzhang Wang
  • Jian Cheng
  • Henan Liu
  • Mingjun ChenEmail author
  • Chunya WuEmail author
  • Dingning Su


Complex structural components with small concave surfaces are widely needed in aerospace, optics, and electronic industry. On account of the interference between grinding wheel and workpiece and small concave surfaces, traditional grinding machine cannot realize the grinding process; hence, a specialized grinding machine tool with on-machine electric discharge truing function is needed. After analyzing the structural characteristics and processing requirements of the component, the kinematic chain and configuration were designed. The structure of the machine tool was divided into four function modules, and each module was designed, analyzed, and optimized, respectively. Then the finite element analysis (FEA) of the whole machine tool was conducted including static, modal, and harmonic response analysis to verify the performance of the machine and identify the weak links of the structure loop. The error model was established by screw theory to study the quantitative relationship between the static deformations and processing accuracy. Both finite element analysis and error model can provide guidance for further optimization. Finally, the performance of the machine tool was evaluated by the grinding and on-machine truing experiments, achieving the profile accuracy (PV) of 0.339 μm, surface roughness (Ra) of 50.2 nm, and the grinding wheel surface with diamonds distributing homogeneously. The results indicate that the developed machine tool can well satisfy the processing requirements of the component.


Ultra-precision grinding machine tool Structural design Dynamic performance analysis Harmonic response analysis On-machine electric discharge truing 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


Funding information

This work is supported by the National High Technology Research and Development Program (“863” program) of China [2015AA043301] and The National Key Research and Development Program of China [2018YFB1107600].


  1. 1.
    Brinksmeier E, Mutlugünes Y, Klocke F, Aurich JC, Shore P, Ohmori H (2010) Ultra-precision grinding. CIRP Ann Manuf Technol 59:652–671CrossRefGoogle Scholar
  2. 2.
    Zhong ZW, Venkatesh VC (2009) Recent developments in grinding of advanced materials. Int J Adv Manuf Technol 41:468–480CrossRefGoogle Scholar
  3. 3.
    Shore P, Morantz P, Luo X, Tonnellier X, Collins R, Roberts A, May-Miller R, Read R (2005) Big OptiX ultra precision grinding/measuring system. Proc SPIE 5965:241–248Google Scholar
  4. 4.
    Yamamoto Y, Suzuki H, Moriwaki T, Okino T, Higuchi T (2007) Precision grinding of micro fresnel lens molding die (2nd report): precision truing of micro grinding wheel with sharp edge by molybdenum truer and accuracy improvement in fresnel surface grinding. Int J Jpn Soc Precis Eng 73:688–692CrossRefGoogle Scholar
  5. 5.
    Guo B, Zhao QL (2015) On-machine dry electric discharge truing of diamond wheels for micro-structured surface grinding. Int J Mach Tools Manuf 88:62–70CrossRefGoogle Scholar
  6. 6.
    Lu YJ, Xie J, Si XH (2015) Study on micro-topographical removals of diamond grain and metal bond in dry electro-contact discharge dressing of coarse diamond grinding wheel. Int J Mach Tools Manuf 88:118–130CrossRefGoogle Scholar
  7. 7.
    Weingӓrtner 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 49:1001–1007CrossRefGoogle Scholar
  8. 8.
    Xie J, Tamaki J (2008) Computer simulation of sub-micron-scale precision truing of a metal-bonded diamond grinding wheel. Int J Mach Tools Manuf 48:1111–1119CrossRefGoogle Scholar
  9. 9.
    Weingӓrtner E, Roth R, Kuster F, Boccadoro M, Fiebelkorn F (2012) Electrical discharge dressing and its influence on metal bonded diamond wheels. CIRP Ann Manuf Technol 61:183–186CrossRefGoogle Scholar
  10. 10.
    Cai LR, Li M, Yang H, Hu DJ (2013) Electrical discharge dressing metal-bonded diamond grinding wheels with various mediums. Proc Inst Mech Eng B J Eng Manuf 227:102–108CrossRefGoogle Scholar
  11. 11.
    Huo D, Cheng K, Wardle F (2010) Design of a five-axis ultra-precision micro-milling machine—UltraMill. Part 1: holistic design approach, design considerations and specifications. Int J Adv Manuf Technol 47(9–12):867–877CrossRefGoogle Scholar
  12. 12.
    Son H, Choi HJ, Park HW (2010) Design and dynamic analysis of an arch-type desktop reconfigurable machine. Int J Mach Tools Manuf 50(6):575–584CrossRefGoogle Scholar
  13. 13.
    Zhou M, Qin Y, Harrison C, Brockett A, Ma Y (2010) Finite element and experimental analysis of dynamic behaviors of a micro stamping tool system. Int J Adv Manuf Technol 47:839–844CrossRefGoogle Scholar
  14. 14.
    Liang YC, Chen WQ, Bai QS, Sun YZ, Chen GD, Zhang Q, Sun Y (2013) Design and dynamic optimization of an ultraprecision diamond flycutting machine tool for large KDP crystal machining. In J Adv Manuf Technol 69:237–244CrossRefGoogle Scholar
  15. 15.
    Li W, Li BZ, Yang JG (2017) Design and dynamic optimization of an ultra-precision micro grinding machine tool for flexible joint blade machining. In J Adv Manuf Technol 93:3135–3147CrossRefGoogle Scholar
  16. 16.
    Yang B, Xie XH, Zhou L, Hu H (2017) Design of a large five-axis ultra-precision ion beam figuring machine: structure optimization and dynamic performance analysis. In J Adv Manuf Technol 92:3413–3424CrossRefGoogle Scholar
  17. 17.
    Deng CY, Liu Y, Zhao J, Wei B, Yin GF (2017) Analysis of the machine tool dynamic characteristics in manufacturing space based on the generalized dynamic response model. In J Adv Manuf Technol 92:1411–1424CrossRefGoogle Scholar
  18. 18.
    Yin SH, Morita SY, Ohmori H, Uehara Y, Lin WM, Liu Q, Maihara T, Iwamuro F, Mochida D (2005) ELID precision grinding of large special Schmidt plate for fibre multi-object spectrograph for 8.2 m Subaru telescope. Int J Mach Tools Manuf 45:1598–1604CrossRefGoogle Scholar
  19. 19.
    Chen WQ, Liang YC, Sun YZ, Huo DH, Su H, Zhang FH (2015) A two-round design method for ultra-precision flycutting machine tools with stringent process requirements. Proc Inst Mech Eng B J Eng Manuf 229(9):1584–1594CrossRefGoogle Scholar
  20. 20.
    Huo DH, Cheng K, Wardle F (2010) A holistic integrated dynamic design and modelling approach applied to the development of ultraprecision micro-milling machines. Int J Mach Tools Manuf 50:335–343CrossRefGoogle Scholar
  21. 21.
    Park H, Park I, Dang X (2015) Development of an electro-mechanical driven broaching machine. J Korean Soc Manuf Technol Eng 24(1):007–014Google Scholar
  22. 22.
    Wang TZ, Chen J, Liu HN, Chen MJ, Wu CY, Fang Z, Yu B (2018) Effects of kinematic parameters on electric discharge truing of small ball-end diamond wheels for small concave surfaces grinding. Precis Eng 51:117–127CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  1. 1.Center for Precision EngineeringHarbin Institute of TechnologyHarbinPeople’s Republic of China

Personalised recommendations