Characteristic Studies On Oxide Layer By Ultrasonic Vibration And Electrolytic In-process Dressing Combined Grinding Mechanism Of ZTA

Zirconia toughened alumina ceramics are typically difficult to process, which are hard and brittle materials with excellent mechanical properties. Ultrasonic vibration and electrolytic in-process dressing combined grinding is one of the new composite processing methods, which include the advantages of ELID grinding and ultrasonic vibration grinding. The oxide layer on wheel which generates in electrolysis process plays a key role during the ultrasonic vibration and electrolytic in-process dressing combined grinding similar to the ELID grinding. It is of significance to study the thickness, formation rate and the surface topography of the oxide layer for the workpiece surface integrity.This paper focuses on the research on the oxide layer of cast iron bond diamond wheel. On the basis of the analysis of the oxide layer formation and removal, the predictive modeling of oxide layer thickness is proposed and simulated. The result of Matlab software simulation reveals the principle of the oxide layer to the adaptive grinding process. Experimental platform of ultrasonic vibration and electrolytic in-process dressing combined grinding is constructed, including: acoustic system design, handle connecting structure design, ELID electrolytic device anode design, ELID truing device cathode design.According to the principle of EDM machining technology, shaping trials of cast iron bond diamond wheels are carried. Wheel roundness departures and wheel surfaces topography have achieved the required ultrasonic vibration and electrolytic in-process dressing combined grinding standards through adjusting the shaping parameters. The experiments of the ultrasonic vibration and electrolytic in-process dressing combined grinding are carried out to verify the predictive modeling of oxide layer thickness. The voltage, pulse width and pulse interval, inter-electrode gap, wheel speed and ultrasonic vibration influencing conditions of the oxide layer growth are studied and the oxide layer thickness and forming rate are analyzed via single factor test. By changing the wheel speed, workpiece speed, grinding depth and grain size, qualitative analysis of the effects of the parameters on the state of the oxide layer during the grinding process are undertaken. Mechanism of ultrasonic vibration on polishing properties of the oxide layer are revealed by the experiments of polishing grinding test and ultrasonic polishing grinding...