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Zeitschriftenartikel

Modeling of Ultra-Precision ELID grinding

Journal of Manufacturing Science and Engineering (ASME), vol. 129, no. 2, pp. 129-302

2007

Angewandte Naturwissenschaften und Wirtschaftsingenieurwesen Elektrotechnik und Medientechnik Hochschulleitung und -einrichtungen Maschinenbau und Mechatronik

The electrolytic in-process dressing (ELID) grinding is a new and an efficient process for ultra-precision finishing of hard and brittle materials. Unlike conventional grinding processes, the ELID grinding is a hybrid process that consists of a mechanical and an electrochemical process, and the performance of the ELID grinding process is influenced by the parameters of the above said processes. Therefore, it is necessary to develop a new grinding model for the ELID grinding, which can be used to avoid the cumbersome and expensive experimental trials. In this paper, the authors proposed a new grinding model for ultra-precision ELID grinding. The main focus is to develop a force model for the ultra-precision ELID grinding where the material removal is significantly lower than the conventional grinding. When the material removal rate is very low, it is very important to estimate the real contact area between the wheel and work surfaces. The developed grinding model estimates the real contact area by considering the wheel and the work surface characterization and the effect of the electrolytic reaction at the grinding wheel edge. The effects of the microstructure changes on the wheel surface by the electrochemical reaction have been implemented in the model in order to improve the efficiency of the developed model. The grinding model has been simulated and the simulated results are substantiated by the experimental findings.

Vortrag

K. Fathima, Andreas Geiss, J. Slabeycius, Markus Schinhärl, Rolf Rascher, Peter Sperber, Elmar Pitschke

Subsurface damages detecting on standard optical glass by dimple method

The 12th International Conference on Problems of Material Engineering, Mechanics and Design, Jasna, Slowakei

2007

Angewandte Naturwissenschaften und Wirtschaftsingenieurwesen Elektrotechnik und Medientechnik Hochschulleitung und -einrichtungen Maschinenbau und Mechatronik

Beitrag (Sammelband oder Tagungsband)

K. Fathima, Andreas Geiss, Markus Schinhärl, Rolf Rascher, Peter Sperber, Elmar Pitschke

Design and development of a novel computer-controlled power device for electrical-assisted optical grinding

Optifab 2007: Technical Digest, volume TD04

2007

Angewandte Naturwissenschaften und Wirtschaftsingenieurwesen Elektrotechnik und Medientechnik Hochschulleitung und -einrichtungen Maschinenbau und Mechatronik

Beitrag (Sammelband oder Tagungsband)

K. Fathima, Andreas Geiss, J. Slabeycius, Markus Schinhärl, Rolf Rascher, Peter Sperber, Elmar Pitschke

Subsurface damages detecting on standard optical glass by dimple method

Proceedings of the 12th International Conference on Problems of Material Engineering, Mechanics and Design, Jasna, Slowakei

2007

Angewandte Naturwissenschaften und Wirtschaftsingenieurwesen Elektrotechnik und Medientechnik Hochschulleitung und -einrichtungen Maschinenbau und Mechatronik

Beitrag (Sammelband oder Tagungsband)

K. Fathima, Andreas Geiss, J. Slabeycius, Markus Schinhärl, Rolf Rascher, Peter Sperber, Elmar Pitschke

Correcting silicon carbide and silicon nitride moulds by Magnetorheological Finishing

Proceedings of the 7th euspen International Conference, Bremen, Vol. 2

2007

Zeitschriftenartikel

ELID grinding technique for nano finishing of brittle materials

SADHANA - Journal of Engineering Sciences (Indian Academy of Sciences), vol. 28, no. 5, pp. 1-18

2003

Zeitschriftenartikel

A study on wear mechanism and wear reduction Strategies in grinding wheels used for ELID grinding

Wear, vol. 254, no. 12, pp. 1247-1255

2003

Metal-bonded superabrasive diamond grinding wheels have superior qualities such as high bond strength, high stability and high grindability. The major problems encountered are wheel loading and glazing, which impedes the effectiveness of the grinding wheel. Electrolytic in-process dressing (ELID) is an effective method to dress the grinding wheel during grinding. The wear mechanism of metal-bonded grinding wheels dressed using ELID is different form the conventional grinding methods because the bond strength of the wheel-working surface is reduced by electrolysis. The reduction of bond strength reduces the grit-depth-of-cut and hence the surface finish is improved. The oxide layer formed on the surface of the grinding wheel experiences macrofracture at the end of wheel life while machining hard and brittle workpieces. When the wheel wear is dominated by macrofracture, the wheel-working surface is free from loaded chips and worn diamond grits. When the oxide layer is removed from the wheel surface, the electrical conductivity of the grinding wheel increases, and that stimulates electrolytic dressing. The conditions applied to the pulse current influence the amount of layer oxidizing from the grinding wheel surface. Longer pulse ‘on’ time increases the wheel wear. Shorter pulse ‘on’ time can be selected for a courser grit size wheel since that type of wheel needs high grinding efficiency. Equal pulse ‘on’ and ‘off’ time is desired for finer grit size wheels to obtain stable and ultraprecision surface finish.

Beitrag (Sammelband oder Tagungsband)

A study on some factors affecting the mechanism of ELID grinding

International progress on advanced optics and sensors, Tokyo, vol. 40

2003

ISBN: 4-946443-76-2

Zeitschriftenartikel

A Study on the Grinding of Glass Using Electrolytic In-Process Dressing

Journal of Electronic Materials, vol. 31, no. 10, pp. 1039-1046

2002

Grinding of brittle materials such as glass is gaining importance due to the rapid developments in the areas of machining of storage devices, microlenses, and optical communication devices. Grinding of such glasses is difficult because grinding wheels wear out easily due to the hard and brittle nature of the materials being machined. Grinding wheels with fine abrasive size are required in order to achieve ductile mode grinding. Problems such as wheel loading and glazing can be encountered while grinding with fine abrasive wheels. Electrolytic in-process dressing (ELID) is an efficient method to dress the grinding wheel while performing grinding. In this paper, a fundamental study on the mechanism of the ELID grinding technique is discussed in detail. Several sets of experiments have been performed to determine the optimal grinding conditions. From the experiments, it has been established that surface roughness could be further improved if the current duty ratio to dress the grinding wheel were increased. The force patterns and the changes in the profile of the grinding wheel during machining are also presented and discussed in detail.

Zeitschriftenartikel

DOI: 10.1016/S0890-6955(02)00023-8

Fundamental study on the mechanism of electrolytic in-process dressing (ELID) grinding

International Journal of Machine Tools and Manufacture, vol. 42, no. 8, pp. 935-943

2002

Demands for high quality surface finish, dimensional and form accuracy are required for optical surfaces and it is very difficult to achieve these using conventional grinding methods. Electrolytic in-process dressing (ELID) grinding is one new and efficient method that uses a metal-bonded diamond grinding wheel in order to achieve a mirror surface finish especially on hard and brittle materials. However, studies reported so for have not explained the fundamental mechanism of ELID grinding and so it has been studied here by conducting experiments to establish optimal grinding parameters to obtain better surface finish under various in-process dressing conditions. In this research the results show that the cutting forces are unstable throughout the grinding process due to the breakage of an insulating layer formed on the surface of the grinding wheel; however, a smoother surface can be obtained using a high dressing current duty ratio at the cost of high tool wear. ELID grinding is efficient for feed rates of less than 400 mm/min, and surface cracks are observed when it exceeds this limit.

Beitrag (Sammelband oder Tagungsband)