Abstract
Recent developments in grinding have opened up new avenues for finishing of hard and brittle materials with nano-surface finish, high tolerance and accuracy. Grinding with superabrasive wheels is an excellent way to produce ultraprecision surface finish. However, superabrasive diamond grits need higher bonding strength while grinding, which metal-bonded grinding wheels can offer. Truing and dressing of the wheels are major problems and they tend to glaze because of wheel loading. When grinding with superabrasive wheels, wheel loading can be avoided by dressing periodically to obtain continuous grinding. Electrolytic inprocess dressing (ELID) is the most suitable process for dressing metal-bonded grinding wheels during the grinding process. Nano-surface finish can be achieved only when chip removal is done at the atomic level. Recent developments of ductile mode machining of hard and brittle materials show that plastically deformed chip removal minimizes the subsurface damage of the workpiece. When chip deformation takes place in the ductile regime, a defect-free nano-surface is possible and it completely eliminates the polishing process. ELID is one of the processes used for atomic level metal removal and nano-surface finish. However, no proper and detailed studies have been carried out to clarify the fundamental characteristics for making this process a robust one. Consequently, an attempt has been made in this study to understand the fundamental characteristics of ELID grinding and their influence on surface finish.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Bandyopadhyay B P, Ohmori H 1999 The effect of ELID grinding on the flexural strength of silicon nitride.Int. J. Machine Tools Manuf. 39: 839–853
Bandyopadhyay B P, Ohmori H, Takahashi I 1996 Ductile regime mirror finish grinding of ceramics with electrolytic in-process dressing (ELID) grinding.Mater. Manuf. Proc. 11: 789–801
Fujihara K, Ohshiba K, Komatsu T, Ueno M, Ohmori H, Bandyopadhyay B P 1997 Precision surface grinding characteristics of ceramic matrix composites and structural ceramics with electrolytic inprocess dressing.Machining Sci. Technol. 1: 81–94
Itoh N, Ohmori H, Moriyasu S, Kasai T, Toshiro K, Bandyopadhyay B P July 1998 Finishing characteristics of brittle materials by ELID-lap grinding using metal-resin bonded wheels.Int. J. Machine Tools Manu. 38: 747–762
Kato T, Ohmori H, Zhang C, Yamazaki T, Akune Y, Hokkirigawa K 2001 Improvement of friction and wear properties of CVD-SiC films with new surface finishing method ‘ELID-grinding’Key Eng. Mater. 196: 91–101
Kumar A S, Lim H S, Rahman M, Fathima K 2002 A study on grinding of glass using electrolytic in-process dressing (ELID) grinding.J. Electron. Mater. 31: 1039–1046
Lee E S 2000 A study of the development of an ultraprecision grinding system for mirror-like grinding,Int. J. Adv. Manuf. Technol. 16: 1–9
Lim H S, Ohmori H, Lin W, Qian J 2000 High productivity and high accuracy electrode-less ELID grinding on die material.J. Mould Tehcnol. 15: 148–149 (in Japanese)
Lim H S, Ohmori H, Lin W, Qian J 2001 Electrode-less micro ELID grinding on die and mould material.J. Soc. Grinding Eng. 45: 298–303
Lim H S, Fathima K, Kumar A S and Rahman M 2002 A fundamental study on the mechanism of electrolytic in-process dressing (ELID) grinding.Int. J. Machine Tools Manuf. 42: 935–943
Murata R, Okano K, Tsutsumi C 1985 Grinding of structural ceramics.Milton C Shaw Grinding Symposium PED 16: 261–272
Ohmori H, Nakagawa T 1990 Mirror surface grinding of silicon wafers with electrolytic in-process dressing.Ann. CIRP 39/1: 329–333
Ohmori H, Nakagawa T 1995 Analysis of mirror surface generation of hard and brittle materials by ELID (electronic in-process dressing) grinding with superfine grain metallic bond wheels.CIRP Ann.-Manuf. Technol. 44: 287–290
Ohmori H, Nakagawa 1997 Utilization of nonlinear conditions in precision grinding with ELID (electrolytic in-process dressing) for fabrication of hard material components.CIRP Ann. Manuf. Technol. 46: 261–264
Ohmori H, Qian J 2000 ELID-II grinding of micro spherical lens.RIKEN Rev. 23: 140
Ohmori H, Moriyasu S, Li W, Takahashi I, Park KY, Itoh N, Bandyopadhyay B P 1999 Highly efficient and precision fabrication of cylindrical parts from hard materials with the application of ELID (electrolytic in-process dressing).Mater. Manuf. Proc. 14: 1–12
Ohmori H, Li W, Makinouchi A, Bandyopadhyay B P 2000 Efficient and precision grinding of small hard and brittle cylindrical parts by the centerless grinding process combined with electro-discharge truing and electrolytic in-process dressing.J. Mater. Proc. Technol. 98: 322–327
Okuyama S, Yonago M, Kitajima T, Suzuki H 2001 A basic study on the combination machining of ELID-grinding and EDM-experiments of combination machining using a pulse power-source.J. Jpn. Soc. Precision Eng. 67: 407–412
Qian J, Wei L, Ohmori H 2000 Cylindrical grinding of bearing steel with electrolytic in-process dressing.Precision Eng. 24: 153–159
Qian J, Ohmori H, Lin W 2001 Internal mirror grinding with a metal/metal-resin bonded abrasive wheel.Int. J. Machine Tools Manuf. 41: 193–208
Shimada S, Ikawa N, Inamura T, Takezawa N, Ohmori H, Sata T 1995 Brittle-ductile transition phenomena in microindentation and micromachining.CIRP Ann.-Manuf. Technol. 44: 523–526
Stephenson D J, Veselovac D, Manley S, Corbett C 2001 Ultra-precision grinding of hard steels.Precision Eng. 25: 336–345
Stephenson D J, Hedge J, Corbett J 2002 Surface finishing of Ni-Cr-B-Si composite coatings by precision grinding.Int. J. Machine Tools Manuf. 42: 357–363
Suzuki K, Uematsu T, Nakagawa T 1987 On-machine truing/dressing of metal-bonded grinding wheels by electro-discharge machining.CIRP Ann. 36: 115–118
Uehara Y, Ohmori H, Yamagata Y, Moriuasu S, Makinouchi A, Morita S 2001 Microfabrication grinding by ultraprecision microform generating machine employed with plasma discharge truing and ELID techniqueRIKEN Rev. 34: 25–28
Venkatesh V C, Inasaki I, Toenshof H K, Nakagawa T, Marinescu I D 1995 Observations on polishing and ultraprecision machining of semiconductor substrate materials.CIRP Ann.-Manuf. Technol. 44: 611–618
Wang P, Shi Z, Xin Q2000 Optical surface grinding of optical glasses with ELID grinding technique.Proc SPIE Int. Soc. Opt. Eng. 4231: 509–514
Zhang F, Li W, Qiu Z, Ohmori H 2000 Application of ELID grinding technique to precision machining of optics.Proc. SPIE-Int. Soc. Opt. Eng. 4231: 218–223
Zhanga C, Ohmori H, Kato T, Morita N 2001 Evaluation of surface characteristics of ground CVD-SiC using cast iron bond diamond wheels.Precision Eng. 25: 56–62
Zhang Bi, Yang F, Wang J, Zhu Z, Monahan R 2000 Stock removal rate and workpiece strength in multi-pass grinding of ceramics.J. Mater. Process. Technol. 104: 178–184
Zhang C, Ohmori H, Li W 2000 Small-hole machining of ceramic material with electrolytic interval-dressing (ELID-II) grinding.J. Mater. Process. Technol. 105: 284–293
Author information
Authors and Affiliations
Rights and permissions
About this article
Cite this article
Rahman, M., Kumar, A.S., Lim, H.S. et al. Nano finish grinding of brittle materials using electrolytic in-process dressing (ELID) technique. Sadhana 28, 957–974 (2003). https://doi.org/10.1007/BF02703325
Issue Date:
DOI: https://doi.org/10.1007/BF02703325