The fluid flow problem in a traditional electrolytic in-process dressing (ELID) system is analyzed and solved numerically. The predicted mean velocity profiles in the dressing zone show flow patterns that are in good agreement with the mean velocity distributions for plane laminar/turbulent Couette flows observed in the experiments. The computational results reveal that insufficient electrolyte supply rate is the cause of the failure of the traditional ELID system for high-speed grinding. Results also show that to obtain effective high-speed ELID grinding, a consistent high inlet electrolyte velocity or supply rate is required. For the foil ELID system, governing equations describing the fluid flow in the dressing zone and the foil elastic deformation are formulated. Analytical solution based on unidirectional flow model for the problem is presented and effects of wheel surface speed and foil tension on the performance of the dressing system are discussed. It is shown that the foil ELID system has the potential to be effective for high-speed grinding with low electrolyte supply rates. The results will be useful to the development of new machine systems and processes for high-speed grinding.
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August 2004
Technical Papers
Simulation and Analysis of Rigid/Foil Electrolytic In-Process Dressing (ELID) Systems for Grinding
Zhenqi Zhu,
Zhenqi Zhu
Stevens Institute of Technology, Hoboken, NJ 07030
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Xiaohua Wang,
Xiaohua Wang
Stevens Institute of Technology, Hoboken, NJ 07030
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Siva Thangam
Siva Thangam
Stevens Institute of Technology, Hoboken, NJ 07030
Search for other works by this author on:
Zhenqi Zhu
Stevens Institute of Technology, Hoboken, NJ 07030
Xiaohua Wang
Stevens Institute of Technology, Hoboken, NJ 07030
Siva Thangam
Stevens Institute of Technology, Hoboken, NJ 07030
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received April 10, 2003; Revised February 4, 2004. Associate Editor: K. Rajurkar.
J. Manuf. Sci. Eng. Aug 2004, 126(3): 565-570 (6 pages)
Published Online: September 7, 2004
Article history
Received:
April 10, 2003
Revised:
February 4, 2004
Online:
September 7, 2004
Citation
Zhu , Z., Wang , X., and Thangam , S. (September 7, 2004). "Simulation and Analysis of Rigid/Foil Electrolytic In-Process Dressing (ELID) Systems for Grinding ." ASME. J. Manuf. Sci. Eng. August 2004; 126(3): 565–570. https://doi.org/10.1115/1.1765152
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