Analysis of ELID-grinding mechanism based on an in-process observation

利用CCD显微镜摩擦系统对elid磨削过程进行了观察，研究了其磨削机理。利用ELID电解的作用，在砂轮试样表面形成氧化膜。得到以下结论：(1)采用带氧化层的400 #砂轮作圆盘试样，干燥条件下摩擦系数为0.23 ~ 0.58，润滑条件下摩擦系数为0.11 ~ 0.38。(2)采用带有氧化层的4000 #砂轮作圆盘试样时，干燥条件下摩擦系数为0.16 ~ 0.76，润滑条件下摩擦系数为0.15 ~ 0.38。(3)当接触压力大于1.2MPa时，有氧化层的铸铁结合剂砂轮的比磨损率（w_s= 1.0×10^<-6>mm^2/N ~ 9.7×10^<-5>mm^2/N）大于无氧化层的铸铁结合剂砂轮（w_s=7.1×10^<-7>mm^2/N ~ 2.9×10^<-6>mm^2/N）。(4)利用软平面与硬投影之间的磨损图，研究了ELID砂轮对金刚石颗粒多点接触的微观机理。从实际应用的角度，提出了elid磨削结合材料发展的指标。具体而言，通过对砂轮磨损进行数值化处理，对无金属导电树脂结合材料与铸铁结合材料的磨损量进行了估算。在此基础上，建立了对elid砂轮开发阶段材料设计的反馈系统。

Mechanism of ELID-grinding was investigated in this research based on an in-process observation by using a CCD Microscope tribosystem. The oxidation film was generated on the surface of the grinding wheel test specimen by using the effect of the ELID electrolysis. The following conclusions were obtained ; (1) When #400 grinding wheel with oxide layer is used for disk specimen, the friction coefficient shows 0.23〜0.58 under dry condition, and it shows 0.11〜0.38 under lubrication. (2) When #4000 grinding wheel with oxide layer is used for disk specimen, the friction coefficient shows 0.16〜0.76 under dry condition, and it shows 0.15〜0.38 under lubrication condition. (3)When the contact pressure is more than 1.2MPa, specific wear rate(w_s) of cast iron bonded grinding wheel with oxide layer (w_s =1.0×10^<-6>mm^2/N〜9.7×10^<-5>mm^2/N) is lager than that of cast iron bonded grinding wheel without oxide layer (w_s=7.1×10^<-7>mm^2/N〜2.9×10^<-6>mm^2/N). (4) The microscopic mechanism of the ELID grinding wheel for the multi point contact of diamond grain was examined by using the wear map between soft plane and a hard projection. From a practical side, indicator for the ELID-grinding bond material development was proposed. Concretely, wear of metal-free electro-conductive resin bonded material are estimated compared with the cast iron bonded material since moderate range of wear of ELID-grinding wheel is made to the numerical value. By using these results, the feedback system was constructed to the material design at the development stage of ELID-grinding wheel.