Journal of Mechanical Science and Technology 22 (2008) 2197~2202
www.springerlink.com/content/1738-494x
DOI 10.1007/s12206-008-0710-4
Journal of
Mechanical
Science and
Technology
Design of continuity processes of electrochemical finishing
and grinding following turning
†
P. S. Pa
*
Graduate School of Toy and Game Design, National Taipei University of Education
No.134, Sec. 2, Heping E. Rd., Taipei City 106, Taiwan
(Manuscript Received April 28, 2008; Revised July 3, 2008; Accepted July 15, 2008)
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Abstract
A newly designed finishing process utilizing an effective electrode and a grinding tool to execute the continuous
electrochemical finishing and grinding processes following turning is described in this paper. The proposed process can
be used for a variety of turning operations. Electrochemical finishing and grinding can be performed following the
finishing process on the same machine by using a simple attachment. The factors affecting electrochemical finishing,
grinding performance, and electrochemical finishing are discussed. The electrode was tested with both continuous and
pulsed direct current. A higher work piece rotational speed produced a better finish. Changing the electrode design
from a semicircle to a wedge form with a small end radius caused the electrolytic products and heat to dissipate more
rapidly and provided the best finishing. Pulsed direct current finishing was slightly better than using continuous direct
current finishing. However, the use of pulsed current would increase machining time and cost.
Keywords:
Continuity processes; Grinding; Electrochemical finishing; Turning; Design; Finishing tool
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1. Introduction
Grinding is the finishing process in mould and die
manufacturing. Surface quality plays a very important
role in the performance of machined parts [1].
Variations in position, velocity, and force trajectories
in the grinding process affect component quality by
changing the surface finish, geometry, and process
material removal rate. Thus, controlling the position,
velocity, and force is critical to achieving a high
quality product from the grinding process [2, 3]. In
continuous grinding operations, the grinding effi-
ciency of vitrified grinding wheels deteriorates as the
sharp cutting edge becomes blunt from the formation
of wear flats. Dressing during the sharpening opera-
tion addresses this problem by generating a specific
topography on the grinding wheel’s cutting face [4].
Electropolishing is used for difficult-to-machine
materials, such as ceramic and cermet. Ceramic and
cermet materials are used for die components, plastic
or press dies, wire-drawing dies, and optical units.
Electropolishing can also be applied to electrolytic
components (silicon chips, VLSI/ULSI chips). Elec-
trochemical machining (ECM) was originally des-
cribed by Faraday in the eighteenth century who used
electric energy and chemical processes to remove
materials [5]. The main difficulty in the complicated
process of metal removal is the design of the tool
electrode. The electrochemical hole machining
process improves hole precision by controlling
machining conditions and electrode geometry [6].
The gap width between the electrode and work piece
directly influences the current condition and the dreg
discharge of the electrolyte [7]. The quality of the
machined surface will be influenced by current
density, electrolyte flow rate, and the gap width in
†This paper was recommended for publication in revised form by Associate
Editor Dae-Eun Kim
*
Corresponding author. Tel.: +886 2 2732 1104 ext: 2214, Fax.: +886 2 2305 5280
E-mail address: myhow@seed.net.tw
© KSME & Springer 2008