The Surface Roughness Prediction Model And Experimental Research On ELID Form Grinding

ELID form grinding is the application of ELID(Electrolytic In—process Dressing)technology in form grinding,which can significantly solve the problems in form grinding process such as the blocked wheels and the difficulty in dressing,it can extend the wheel's life and improve the form precision of the workpiece.Surface roughness is an important evaluation parameter for the ELID form grinding,which affects surface quality of the parts.The surface roughness prediction model can provide the scientific guide for the selection of technological parameters in the process of grinding.In this paper,a surface roughness prediction model is established according to the characteristics of the ELID form grinding.A series of experiments are conducted in straight groove and bearing ring using ELID form grinding,and the influence of process parameters on surface roughness have been studied.The undeformed chip thickness and surface roughness are closely related.In this paper,based on the undeformed chip thickness model,a surface roughness theory prediction model is established considering the abrasive's overlapping and the plastic bulge in the cut-in form grinding and the effect of electrolytic parameters.The model is proved to have a good agreement with the experiment.The straight groove ELID form grinding experiment is carried out using single factor method,which studied the effect of the workpiece speed,the cutting depth,the power supply voltage and the electrolytic current on the surface roughness.The results show that the surface roughness increases with the workpiece speed,the cutting depth and the current,while decreases with the power supply voltage.The state of oxider layer in different setting current is observed,it indicates that the change of electrolytic parameters leads to the change of the oxider layer's state,then causes the change of surface roughness.Using the orthogonal experiment method,the experiment on ELID form grinding for the ring raceway is carried out.And the influence for the wheel speed,workpiece speed,the radial feed speed and the electrolytic current on surface roughness is studied.According to the residual analysis,the workpiece speed and the radial feeding speed make a greater influence on surface roughness.The surface roughness prediction model reveals the effect of process parameters on surface roughness in ELID form grinding,and provides a guidance for practical machining experiment.It can also optimize the process parameters and improve the efficiency and surface quality,which is of great significance.