Precision dressing of arc-shaped coarse-grained diamond wheels via electrical discharge aided grinding technology

High-precision dressing of coarse-grained arc-shaped diamond grinding wheels is one of the research hotspots in the field of precision grinding. However, the dressing of coarse-grained grinding wheels is very difficult. The electrical discharge aided grinding (EDAG) dressing technology has been innovatively proposed, which can achieve high efficiency and precision dressing of coarse-grained arc-shaped diamond grinding wheels. The material removal mechanism of the EDAG dressing method has been thoroughly analyzed. Orthogonal experiments were designed to analyze the influence of process parameters on dressing efficiency and tool loss, the rough dressing was carried out to improve dressing efficiency, and the precision dressing was carried out to improve dressing accuracy. For the concave and convex arc-shaped grinding wheel dressing with the design radius of 3 mm, the radius size errors of concave and convex arcs after rough dressing are 4.43% and 2.69%, respectively. The PV value of profile accuracy is 54.34 μm. The radius size errors of concave and convex arcs after precision dressing are 0.17% and 0.053%, respectively. The PV value of profile accuracy is 17.28 μm. Finally, the radius size errors of concave and convex arc-shaped obtained by grinding silicon carbide ceramic specimens are 0.24% and 0.045%, respectively. The surface roughness of workpiece is up to 463 nm. Thus, the EDAG dressing technology can achieve high-precision dressing of arc-shaped coarse-grained diamond grinding wheels. © The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2024.