Jackson Mark. Machining with Abrasives
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4.8.1 Electrolytic In-process Dressing
Electrolytic in-process dressing (ELID) is an electro-assisted conditioning method
that is in widespread use. With ELID the metal bond is removed continuously
during the grinding process in accordance with the principle of anodic metal
dissolution in electrolysis, whereby the blunt grits are continuously dissolved
from the grinding wheel and the sharp grits below are exposed. ELID is used
mainly for fine-grained metal bonded diamond grinding wheels [13]. It can also
be used for fine-grained tough metal-bond CBN wheels in the grinding of ceramics.
In this process, with ELID the protrusion of the CBN grits is controlled before and
during grinding. Cast iron bonds and cast iron fibre-bonds are the most suitable
bonds for ELID [7]. The ELID grinding setup and the mechanism of action of ELID
are shown in Fig 4.59.
An ELID system essentially consists of a metal bonded grinding wheel, a counter-
electrode and a DC pulse power supply, and also an electrolytic coolant with a high pH
(Fig. 4.59a). The grinding wheel, which acts as the anode in the electrolysis cell, is
connected via a brush contact on the wheel spindle to the positive pole of the power
generator. The counter-electrode, which is adapted to the profile of the wheel, and acts
as the cathode, is made of copper and is placed at a distance of 0.1–0.3 mm to the
grinding wheel [7, 68]. The negative electrode must cover at least one sixth of the
wheel’s active surface and a width that is two millimetres wider than the wheel rim
thickness [7]. The electrolytic coolant has low specific conductivity in the range from
1 to 3 mS/cm. As well as being supplied into the machining area itself, the coolant is
injected directly into the gap between the wheel and the counter-electrode by
additional nozzles [68].
The ELID grinding process consists of three stages: the set-up stage, the
electrolytic pre-sharpening stage, and the ELID cycle stage [69]. The set-up
fine adjuster
for electrode
workpiece
elider
(generator)
electrolyte
+−
electrode
ELID setup
ab
ELID mechanism
Fig. 4.59 Schematic of the ELID grinding setup and mechanism of action
4 Dressing of Grinding Wheels 235
stage takes place with a newly fitted grinding wheel, with balancing and precision
profiling minimizing the run-out of the wheel. This stage should achieve a run-out
of less than 2–4 mm[7]. After profiling, the grits and the bond are at equal height
(Fig. 4.59b). In the pre-sharpening stage the grit protrusion needed at the start
of the grinding process is produced by electrolysis (Fig. 4.59b-1). At this stage
the wheel surface has good conductivity, and hence the current is as great a s that
set at the power supply [70]. Pre-sharpening is performed at low speed and
takes about 10–30 min [7]. Continuing the electrolysis leads to the forming of
an oxide layer on the surface of the wheel, which acts as an insulating layer
and therefore prevents further oxidation of the wheel. The oxide layer is removed
relatively easily by th e abra sive contact in grinding (Fig. 4.59b-3). If the oxide-
layer reaches a certain thickness during the grinding operation, the electrolysis is
started again automatically (Fig. 4.59b-4), as a result of which the blunt grits are
removed from the grinding wheel and the sharp grits below are exposed.
This cycle is called the ELID cycle, which occurs repeatedly throughout the
grinding process [70]. The rate at which bond material is removed is set by
the ELID parameters, namely voltage, current and the gap between the electrodes.
The rate of bond removal should correspond to the development of wear on the
abrasive grits [7].
ELID can be used with various methods such as surface grinding, side grinding,
double-side grinding and lapping. With the ELID technique, so far both hard and
brittle optical and non-optical materials have been ground, including ceramics, hard
steels, ceramic glass, ceramic coatings, biomedical materials, etc., with different
shapes (plane, cylindrical external and internal, spherical and aspherical lenses,
etc.) and very different sizes [7]. With ELID, improvements can be achieved
in terms of both dimensional accuracy and roughness. Electrolytic in-process
dressing can however be used efficiently above all in the manufacture of optical
and ultra-precision components [68]. For some applications ELID grinding can
eliminate polishing and/or lapping operations. With ELID grinding, for example on
brittle materials an extremely fine surface in the nanometre range (4–6 nm) can be
produced [78].
4.8.2 Electro-Discharge Dressing and Electrocontact
Discharge Dressing
Electro-discharge dressing (EDD) works by the principle of therma l m aterial
removal in electro-discharge machining (EDM). With this process the metal
bond of the grinding wheel is removed by the extreme heat th at is generated by
the discharges of sparks between the bond and a counter-electrode (the tool).
The grinding wheel and the tool are connected as electrodes to a direct current
source with a pulsatin g voltage. With EDD the electric discharge takes place in
a non-conductive liquid, the dielectric. As with EDM, the task of the dielectric
is to bundle the discharges at the point where the gap width is smallest, where
236 T. Tawakoli and A. Rasifard
a discharge channel forms. Hence, with the electric discharge sparks of extremely
high temperatures are produced in the discharge zone, as a result of which
the bond material melts rapidly and some evaporates. The gap width between
the wheel and the dressing counter-electrode has to be regulated precisely by a
special control system, which makes the process a complex task [71]. For
this reason, based upon EDD a new conditioning method has been developed,
namely electrocontact discharge dressing (ECDD) [72–74]. The setup of the
system and the mechanism of action of ECDD are shown in Fig. 4.60.Unlike
with EDD, with ECDD no dielectric is injected into the gap between the e lectr o-
des. Therefore, with this process the bond material is not removed by t he
discharges of sparks, as is the case with EDD, but by arc discharges. Due to
the counter-electrode continuously being f
ed
into the grinding wheel, chips and
particles of electrode become present in the cutting edge space of the abrasive
layer. Because of the voltage applied, electric discharges are produced betwe en
these chips and the bond of the wheel, as a result of which the bond is removed by
the action of heat. With this method not only can the wheel be sharpened in one
process, but to a limited extent it can also be profiled [13]. Compared with
conventional conditioning methods, the conditioning time with ECDD is shorter
and it produces a clearly higher maximum profile peak height on the wheel
(Fig. 4.61). E CDD is therefore an economically attractive alternative to other
methods [75].
Fig. 4.60 Schematic of the ECDD grinding setup and mechanism [75] used with permission
copyright Institute of Production Engineeringand Machine Tools (IFW), University Hannover
4 Dressing of Grinding Wheels 237
4.9 Conclusions
The behaviour of a grinding wheel is influenced to a great extent by the condition-
ing method. With the conditioning of a grinding wheel, as well as produc ing the
desired profile on the wheel, the process should also generate a suitable wheel
topography with sufficient chip spaces and the number of cutting edges required for
the task in hand.
A variety of conditioning methods and tools are available now. However,
grinding wheels are conditioned predominantly with diamond dressing tools. The
behaviour of a diamond dresser is, however, determined by its specifications and
the dressing conditions. Therefor e, when selecting a diamond dresser, as well as
considering what is possible for the machine in terms of the geometry and the
specifications of the grinding wheel that is to be dressed, all aspects of the diamond
material used in the dresser and the dresser manufacturing process must be taken
into account.
In recent decades new, non-conventio nal conditioning processes have also been
developed, such as laser dressing and electro-assisted conditioning. Fine-grained
superabrasive grinding wheels can be conditioned economically with electro-
assisted conditioning methods such as electrolytic in-process dressing (ELID) and
electrocontact discharge dressing (ECDD).
Fig. 4.61 Comparison of the process results achieved with conventional conditioning methods
and ECDD [75] used with permission copyright Institute of Production Engineering and Machine
Tools (IFW), University Hannover
238 T. Tawakoli and A. Rasifard
4.10 Nomenclature
Capital Letters
A (–) material absorbance
A
US
(mm) ultrasonic amplitude
D (mm) diamond grit size
F
0
n
(N/mm) specific normal grinding force
F
0
rd
(N/mm) specific radial dressing force
F
0
t (N/mm) specific tangential grinding force
G (–) grinding ratio
G
d
(–) dressing ratio
H (mm) theoretic wheel profile height
I
d0
(A) electrode current during electrocontact discharge dress-
ing
K (W/(cm
C)) thermal conductivity
K
D
(–) diamond grit concentration
P (W/cm
2
) laser beam intensity
P
m
(W) laser average power
P
t
(mm) total profile height
Q
0
W
(mm
3
/(mm s)) specific material removal rate
Q
0
Ws
(mm
3
/(mm s)) specific sharpening material removal rate
R
a
(mm) average roughness height
R
max
(mm) maximum peak-to-valley height
R
ps
(mm) maximum peak height of the whe el
R
ts
(mm) effective peak-to-valley roughness of the wheel
R
sto
(mm) initial active peak-to-valley roughness of the wheel
R
z
(mm) mean peak-to-valley height
T(
C) temperature
U
d
(–) dressing overlap ratio
U
d(a)
(–) dressing overlap ratio calculated in the axial direction
U
d(c)
(–) dressing overlap ratio calculated along the wheel contour
U
d(bd)
(–) dressing overlap ratio calculated from b
d
U
d(r)
(-) dressing overlap ratio calculated in the radial direction
U
d0
(V) electrode voltage during electrocontact discharge
dressing
€
U
P
(–) overlap ratio of the laser pulse
€
U
S
(–) overlap ratio during the laser dressing
V
0
W
(mm
3
/mm) specific material removal
V
0
Ws
(mm
3
/mm) specific sharpening material removal
W
t
(mm) total waviness height
Small Letters
a
d,real
(mm) real total depth of dressing cut
a
apd
(mm) axial engagement width
4 Dressing of Grinding Wheels 239
a
e
(mm) grinding depth of cut
a
ed
(mm) depth of dressing cut
a
pd
(mm) engagement width
a
rpd
(mm) radial engagement width
b
d
(mm) active width of the dressing tool
d
b
(mm) focus beam diameter
d
g
(mm) grit size
d
R
(mm) dressing roller diameter
d
s
(mm) grinding wheel diameter
f (mm) focal length of the lens
f
ad
(mm) axial dressing feed per grinding wheel revolution
f
d
(mm) dressing feed
f
rd
(mm) radial dressing feed per grinding wheel revolution
f
US
(kHz) Ultrasonic frequency
k (–) model constant
q (–) grinding speed ratio
q
d
(–) dressing speed ratio
n
R
(min
1
) number of dressing roller revolution s per minute
n
rd
(–) number of roll-out roller revolutions
n
sd
(min
1
) number of dressing roller revolution s per minute
r
P
(mm) tip radius of the form roller
r
R
(mm) radius of the dressing roller
r
RO
(mm) radius of the dressing roller at the beginning of the dressing
process
r
R,US
(mm) radius of the dressing roller during the ultrasonic assistance
r
S
(mm) radius of the grinding wheel
r
SO
(mm) radius of the grinding wheel at the beginning of the dressing
process
t (s) time
t
a
(s) spark-out time
t
e
(s) moment of the dresser penetration in the wheel surface
t
0
(s) laser pulse width
v
c
(m/s) cutting speed
v
cs
(m/s) cutting speed during sharpening
v
fad
(mm/min) axial dressing feed rate
v
fdres
(mm/min) dressing feed rate along the wheel contour
v
frd
(mm/min) radial dressing feed rate
v
ft
(mm/min) tangential feed rate
v
R
(m/s) dressing roller peripheral speed
v
sd
(m/s) grinding wheel peripheral during dressing
Greek Letters
a (cm
2
s
1
) thermal difusivity
a
e
(
) penetration angle
240 T. Tawakoli and A. Rasifard
b (
) wheel contour inclination angle b
Dl
D
(mm) wear length of diamond sticks
Dr
R
(mm) radial dressing roller wear
Dr
s
(mm) radial wheel wear
DV
D
(mm
3
) dresser wear in volume
e
Pd
(
) tip angle of the form roller
y (
) full divergent angle of the laser beam
l (mm) ultrasonic wavelength
m (–) grinding force ratio
j
RO
(rad) starting angle of the point of the dressing roller to be looked
j
S
(rad) rotational angle of the grinding wheel
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