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Electro-discharge Grinding: Energy Consumption and Internal Stresses in the

Surface Layer

Conference Paper · April 2010

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16th International Symposium on Electromachining (ISEM XVI)

Electro-discharge Grinding: Energy Consumption

and Internal Stresses in the Surface Layer

A.Golabczak, R.Swiecik
Technical University of Lodz, Department of Production Engineering, Stefanowskiego Str. 1/15,
90-924 Lodz, Poland
*Email: andrzej.golabczak@p.lodz.pl

Abstract
In this work the results has been presented related with influence of the selected electrical parameters of the
AEDG process on the energy consumption and state of the internal stresses in the outer layer at this stage
of process, in comparison to the conventional grinding. The basis of this work has been resembled by
investigations of the deep grinding of surfaces of the titanium alloy Ti6Al4V with using CBM grinding wheel
and sintered carbide S20S with using diamond grinding wheel with metallic binding agent. For the
comparative evaluation of the conventional grinding and AEDG, measurements of the specific grinding
energy, energy of the spark discharge and internal stresses in the surface layer have been used.

Keywords:
Abrasive Electro-discharge Grinding, Grinding Force, Energy Consumption, Internal Stresses

1 INTRODUCTION 2 WORK-STAND, METHOD AND GRINDING

In the latest manufacturing processes the permanent CONDITIONS
tendency has been observed due to the gain of the AEDG grinding tests have been conducted at the
energetic efficiency and shortening of the processing time experimental site equipped with the surface-grinding
with parallel preservation of the dimensions tolerance, machine ECBT8 and impulse discharge generator of the
shape tolerance and outer layer quality of the processed GMP75 type. Test site, presented in our earlier papers
piece. Although, the abilities of efficiency gaining by [12, 13], is equipped with control and measurement
uprising criteria for process parameters are limited. It is circuits for grinding parameters, three-axial piezoelectric
mainly observed in processing of the hardly machinable force gauge 9257B made by KISTLER and computerized
materials akin of titanium alloys or sintered carbide. system for the experimental data logging. For the
Problems related with poor machinability revealed out recording of the working current intensity and voltage
particularly during processes of final manufacturing with drop during discharge the measurement kit has been
using abrasive grinding [1,2]. established, exhibited on Fig. 1.
The one of effective grinding methods of machinery
elements is concurrent use of different forms of energy
during removal of processing allowance, often of different
means of physicochemical impact on processed material
[3-5]. Thanks to them, usability indices of the shape
processing could be improved with parallel diminishing of
the negative results of individual using of the constituent
methods.
In the electro-erosive grinding (AEDG) removal of
processing allowance is the result of synergy between
spark discharge between grinding wheel and processed
material surface and simultaneous cutting with the
abrasive grit of the working surface of the grinding wheel
(CPS) [6-10]. The simultaneous activity of mechanical
energy and energy of the spark discharge leads to the
rise up of the processing efficiency, gain of the Fig. 1 : Scheme of meter circuit courses of electric
processing precision and overall surface quality of the discharge in AEDG process
processed surface.
In this work the investigations have been presented
related with the influence of current impulses generator The scope of investigations include tests of the deep
(tension and intensity of the working current) in the grinding AEDG of the planar samples made of titanium
process of AEDG on the energy consumption due to the alloy Ti6Al4V (dimensions 55x20x5) with using grinding
classical grinding. wheel made of the regular boron azide with metallic
binding agent (CBN 125/100 M75) and samples made of
For the evaluation of the grinding process specific energy sintered carbide S20S (dimensions 60x20x5) with
and energy of spark discharge have been used and diamond grinding wheel also with metallic binding agent
additionally internal stresses distribution in the outer layer (SD 125/100 M75). AEDG process has been conducted in
has been determined. distilled water as a dielectric medium.
In the experiments carried out the input variables of the
grinding process were parameters of the electric impulses
generator i.e. working current voltage and intensity.
Constant parameters comprised of impulses time ti,
repetition time tp and kinematic parameters of the AEDG
process, set up accordingly previous investigations made
by authors [12,13].
For the quantitative evaluation of the compared here
grinding processes the specific energy of grinding and
energy of spark discharge has been used. Consumption
of energy of the AEDG process (limited to the
participation of conventional grinding in the whole
process) has been evaluated from the tangential
component of force and speed of grinding:
E
es  VCGm J / mm 3 (1)
The energy of spark discharge has been determined
basing on runs recorded during AEDG grinding. Signals
of current intensity ie and voltage drop ue has been
recorded with digital oscilloscope HM407 (made by
HAMEG) equipped with voltage probe and current shunt
ISM 5P/50 (made by LEM). Signals recorded in the
oscilloscope have been transmitted to the computer and
energy computations have been carried out with using
HAMEG firmware SP107 allowing digital integration of the
mean discharge energy EEDM :
t
E EDM
  u (t )i(t )dt J  (2)
0
Measurements of the internal stresses in the outer layer
2
have been done with x-ray diffractometry sin ψ, which
relay upon determining real elastic distortions of the
crystallic lattice of the grinded samples [11]. The scope of
tests include determination of the specific internal
stresses WW samples of sintered carbide and titanium
alloy after AEDG grinding and after conventional grinding.
3 EXPERIMENTS
Experimental investigations comprise of grinding tests of
the sintered carbide S20S and titanium alloy Ti6Al4V with
using AEDG and with conventional grinding for
comparison. The span of investigations cover
determination of influence of the:
 electrodes polarization on the specific grinding force
during AEDG grinding,
 working current intensity and voltage drop on the
specific energy of grinding,
 working current intensity and voltage drop on the
energy of spark discharge,
 working current intensity and voltage drop on the
distribution of the internal stresses in the outer layer.
Presented results are related with estimation of the
grinding conditions on allowance removal efficiency and
energy consumption in AEDG process and distribution of
stresses in WW.
3.1 Influence of the electrodes polarization in AEDG
process on the specific force of grinding
Investigation results related with influence of electrodes
polarization on tangential component of the specific force
of grinding are presented on Fig. 2. Tests has been
carried out for positive element polarization (+) when
positive pole has been joined with the vice holding
sample and negative element polarization (-) when
negative pole has been joined with the vice holding
sample.
F't [N/mm]
2,5
grinding pass
sparking pass
2,0
1,5
1,0
0,5
0,0
1 2 3
1- Conventional grinding and sparking out a)
2- AEDG (+) process and conventional sparking out
3- AEDG (-) process and conventional sparking out
F't [N/mm]
2,5
grinding pass
sparking pass
2,0
1,5
1,0
0,5
0,0
1 2 3
1- Conventional grinding and sparking out b)
2- AEDG (-) process and conventional sparking out
3- AEDG (+) process and conventional sparking out
Fig. 2: Comparison of specific tangential grinding force
after conventional grinding and AEDG process: a)
sintered carbide S20S, b) titanium alloy Ti6Al4V:
vs=30 m/s, vf=0.5 m/min, a=20 µm, ti=32 µs, tp=63 µs,
dielectric– distilled water
The results found of the sintered carbide grinding (Fig.
2a) exhibits that AEDG grinding with positive polarization
(+) is ineffective because of lack of the significant
changes of the tangential component of the specific
grinding force during AEDG process (sample 1) in
comparison with conventional grinding (sample 2).
Substantial reduction of the tangential component of the
specific grinding force during AEDG process has been
observed during negative polarization (-) of the machined
element (sample 3). Relative decrease of the specific
grinding force during AEDG with negative polarization has
been at 40% during grinding passes and about 10%
during finishing passes.
Similar tendency one can find during titanium alloy
grinding with this difference that most profitable decrease
of the tangential force has been obtained with positive
polarization (+), not negative (-).
In subsequent stages of investigations performed with
titanium alloy Ti6Al4V only negative polarization (-) has
been used and similarly – only positive polarization (+)
has been used for grinding sintered carbide. Such a
polarization assures greater efficiency of the allowance
removal in AEDG process. Should be stressed that
polarization related phenomena during AEDG process
are not sufficiently recognized so far and is the subject of
further investigations of the authors.
3.2 Influence of the working current intensity and
voltage drop on specific energy of the AEDG
The results presented here are related with influence of
the generator electrical parameters i.e. working current
intensity and voltage drop, on the specific energy of
electro-erosive grinding of sintered carbide and titanium
alloy. Specific energy of the AEDG process has been
determined accordingly equation (1) limited to the
participation of conventional grinding in the whole
process. Test results exhibiting influence of the current
intensity and voltage on the specific grinding energy in
the AEDG process with positive polarization of the object
has been presented on Fig. 3.
25
es [J/mm3]
20
15
10
5 150
200
0
0 4 8 12 25
I [A]
Fig. 3: Effect of working current voltage and intensity on
specific energy for conventional grinding (CG) and AEDG
process of titanium alloy Ti6Al4V: vs=30 m/s,
vf=0.5 m/min, a=20 µm, ti=32 µs, tp=63 µs, dielectric –
distilled water
Presented results of investigations have confirmed
substantial influence of the electro-erosive process on
reduction of the specific grinding energy in comparison
with conventional grinding (SK). The lowest specific
grinding energy of the AEDG process has been obtained
with application of the relatively big current intensity at he
level of 25 A and voltage drop at the level of 200 V. At
these conditions of AEDG grinding, specific grinding
energy has been about 62% lower in comparison with
conventional grinding process. This confirms substantial
participation of the electro-erosive process in the
processing allowance removal.
An advantageous reduction of the grinding energy has
been observed also when applied working current of the
12 A intensity at the voltage drop about 150-200 V giving
energy reduction of about 40÷50% in comparison with
conventional grinding process.
Obtained results acknowledged previous observations of
authors, presented in paper [13], where has been proved
that the increase of intensity and voltage of the working
current cause intensive decrease of the tangential
component of the specific grinding force, which in turn
exhibits increase of the electro-erosive process efficiency.
The influence of working current intensity and voltage
drop on AEDG grinding of the sintered carbide S20S,
carried out with negative object polarization during
grinding passes has been presented on Fig. 4.
Presented results of investigations have confirmed
substantial influence of electro-erosive process on
reduction of the specific grinding energy in comparison
with the conventional grinding (CG). The lowest specific
energy of the AEDG process has been obtained with
application relatively big working current intensity (25 A)
and voltage drop (200 V). At this conditions specific
grinding energy has been about five times lower in
comparison with conventional grinding. This confirms
substantial participation of the electro-erosive process in
the processing allowance removal.
100
es [J/mm3]
80
60
CG
40 100
U [V]
20 150
200
0
0 4 8 12 25
I [A]
Fig. 4: Effect of working current voltage and intensity on
specific energy for conventional grinding (CG) and AEDG
CG process of sintered carbides S20S: vs=30 m/s, vf=0.5
100
U [V]
m/min, a=20 µm, ti=32 µs, tp=63 µs, dielectric – distilled
water
An advantageous reduction of the energy consumption
has been observed also when applied working current of
the 12 A intensity at the voltage drop in the range
150-200 V giving energy reduction of about 3.5 times for
the whole voltage range in comparison with conventional
grinding process.
Obtained results acknowledged previous observations of
authors, presented in paper [12], where has been proved
that the increase of intensity and voltage of the working
current cause intensive decrease of the tangential
component of the specific grinding force, which in turn
exhibits increase of the electro-erosive process efficiency.
3.3 Evaluation of the spark discharge energy in the
AEDG process
Measurements of the discharge energy have been carried
out at the test site presented on Fig. 1. Measurement set
allowed recording of the working current intensity and
voltage drop during spark discharges which energy has
been determined accordingly to the formula (2).
Investigations have been made for three ranges of
electrical parameters marked as P1, P2, P3, which have
been set up basing on results presented in papers [12,
13]. These ranges are as follows:
 P1: U=100V, I=8A,
 P2: U=150V, I=12A,
 P3: U=200V, I=25A.
Sample results of the current impulses recorded during
AEDG grinding have the titanium alloy and sintered
carbide are presented on Fig. 5. They have established
basis for evaluation of the energy of the spark discharge
during AEDG process. The influence of the electric
generator parameters choice on the energy of spark
discharges has been depicted on the Fig. 6.
Results presented on Fig. 6. exhibits that along with the
increase of the current intensity and voltage drop grouped
from P1 to P3, increase also the energy of spark
discharge. The greatest value of the spark discharge
energy has been obtained when applied current
parameters from the set P3. They are respectively greater
by 64% for the titanium alloy Ti6Al4V and by 58% for
sintered carbide S20S in comparison with the results
obtained after application of the set P 1 in the AEDG
grinding process. Substantially lower growth of energy, at
the level 49%÷46%, has been observed when applying
sets P2 for grinding both samples.

Fig. 5: Sample record of electrical impulses: voltage drop
of electrical discharge ue and current intensity ie during
AEDG process: a) titanium alloy Ti6Al4V (+), b) sintered
carbide S20S (-); U=150 V, I=12 A, a=20 µm, vs=30 m/s,
vf =0.5 m/min, dielectric – distilled water
500 sintered carbides S20S
EEDM [J]
450 titanium alloy Ti6Al4V
400
350
300
250
200
150
100
50
0
P1 P2
P1: U=100V, I=8A, P2: U=150V, I=12A, P3: U=200V, I=25A
Fig. 6: Influence of the selected electric parameters of
generator on energy of the spark electric discharges:
ti=32 µs, tp=63 µs, a=20 µm, vs=30 m/s, vf=0.5m/min,
dielectric – distilled water
Results presented on Fig. 6. exhibits that along with the
increase of the current intensity and voltage drop grouped
from P1 to P3, increase also the energy of spark
discharge. The greatest value of the spark discharge
energy has been obtained when applied current
parameters from the set P3. They are respectively greater
by 64% for the titanium alloy Ti6Al4V and by 58% for
sintered carbide S20S in comparison with the results
obtained after application of the set P 1 in the AEDG
grinding process. Substantially lower growth of energy, at
the level 49%÷46%, has been observed when applying
sets P2 for grinding both samples.
The increase of discharge energy in the AEDG process
exhibits clearly greater share of electro-erosion in
removal of the processing allowance and lower share of
the machining energy of the abrasive grit CPS. Further
confirmation of this fact are numerous craters, which have
arisen on the grinded surface of the samples of sintered
carbide (SEM pictures are presented in the paper [12]),
which subsequently leads to deterioration of the surface
roughness and substantial decrease of the grinding
forces.
When applying lower current intensities and voltage
drops, lower energies of the spark discharge are gained
which in turn exhibits greater share of the machining
energy with abrasive grit in removal of the processing
allowance. Microscopic examination of the surface after
ADEG grinding in this range of electrical parameters
uncovered only a few craters.
3.4 Evaluation of the internal stresses after AEDG
Comparison has been made between the internal
stresses state in the outer layer of the titanium alloy and
sintered carbide, which has arisen after conventional
grinding and AEDG process. Internal stresses of the outer
layer have been examined. Internal stresses in the outer
layer have been determined with using x-ray diffraction
2
method sin Ψ. The internal stresses calculations have
been performed upon the diffraction diagrams obtained at
the constant angle of the x-ray beam incidence on the
investigated sample. An example of the diffraction pattern
for sintered carbides is presented on Fig. 3.
Fig. 7: Diffraction pattern of sintered carbide S20S (AEDG
U = 150V, I = 12A) obtained at the constant angle of the
incident beam.
P3
The measurements of the internal stresses have been
conducted for three samples after AEDG at the conditions
mentioned in the point 3.3. These measurements have
been performed for five different values of the x-ray beam
incidence angle, which correspond to the following depths
of the internal stresses deposition: 0.2, 0.3, 0.7, 1.5, 2.5
µm. The results of the internal stresses measurements of
the sintered carbides are presented on Fig. 8.
The analysis of the investigations exhibits that in the very
thin surface layer (< 0,3 µm) positive, stretching internal
stresses are deposited in all of the samples. The values
of this stresses ale differentiated, however, because in
the samples grinded at the presence of middle electrical
voltages (100÷150V) and current intensities (8÷12A) the
values of the internal stresses were lower in comparison
with the conventional grinding at the level of about
100÷200%.

Fig. 8: Comparison of the internal stress in the surface
layer of the sintered carbide after conventional grinding
and AEDG.
This advantageous tendency of the internal stresses
distribution has been observed also at the greatest depth
level of the surface layer i.e. 2.5 µm, at which negative,
compressing internal stresses has been occurring after
conventional grinding and AEDG with share of middle
current voltage and intensity. Although, should be
stressed that greatest negative stresses have been
founded for AEDG with share of the middle current
voltage and intensity (150V-12A).
The investigations have proved, that conducting AEDG
with relatively big current voltage and intensity (U=200V,
I=25A) cause stretching stresses in the WW.
Machining conditions and the following mechanism of the
processing allowance removal plays principal role on the
surface layer features. The results of the internal stresses
in the surface layer of the titanium alloy, made with the
2
sin Ψ x-ray diffraction method at the depth of about
20 µm, have been presented in the Tab. 1.
Internal stress value
Process type
 [MPa]
CG
-284.7 ± 19.5
Conventional grinding
AEDG process
-208.5 ± 25
P1: (U=100V, I=8A)
AEDG process
-50.4 ± 7.6
P2: U=150V, I=12A)
AEDG process
181.6 ± 4.5
P3: (U=200V, I=25A)
a = 20 µm, vs = 30 m/s, vf = 0.5 m/min,
dielectric – distilled water
Tab. 1: The results of the internal stress in surface layer
of Ti6Al4V titanium alloy after conventional and AEDG
process grinding.
The results of investigations presented in the Tab. 1.
pointing out that the temperature in the machining zone
substantially affects type and value of the internal
stresses. Experiments have proved out, that conventional
grinding makes some component of the stresses tensor
negative. This advantageous tendency of the internal
stresses shaping one can observe in the AEDG process
also, but detailed differentiation of these parameters
depends upon the specific parameters of the AEDG
process.
The measured internal stresses of the surface layer of the
titanium alloy samples after electro-erosive grinding at low
and middle current voltage and intensity (P1, P2) are of
compression type but after applying big current voltage
and intensity (P3) these stresses became stretching.
The growth of the current voltage and intensity up to the
level of 200V and 25A in the AEDG processing of the
titanium alloy can lead to the growth of the thermal
influence of the spark discharges as well as in the case of
sintered carbide processing. The most probable cause of
this effect is relatively big speed of heating and cooling of
the surface layer in the zone of object grinding wheel
contact. This can lead to the growth of thermal stresses
and bring about disadvantageous distribution of the
internal stresses. Damage of the abrasive grits (CPS) in
the AEDG process is also possible following thermal
effects of the spark discharge as well as dropping out of
the abrasive grits from CPS, which is depicted on Fig. 9b.
a) b)
Fig. 9: SEM analysis of diamond grinding wheel for
sintered carbide: a) after conventional grinding, b) after
AEDG process at middle voltage/current settings.
4 SUMMARY
The conducted investigations have revealed substantial
influence of the electrical parameters (current voltage and
intensity) of the AEDG process on the specific energy of
grinding. It has been proved that conducting AEDG
process with relatively big values of current voltage and
intensity (U=200V, I=25A) cause the specific energy of
grinding to be 4÷5 times lower in comparison with
conventional grinding.
The presented results of experiments confirm that
following the growth of working current voltage and
intensity, the spark discharge energy is also growing,
which assures high efficiency of the processing allowance
during AEDG process.
The conducted investigations have revealed also
influence of the electrical parameters (current voltage and
intensity) of the AEDG process on the internal stresses of
the surface layer. It has been proved that conducting
AEDG with relatively big values of the current voltage and
intensity (U=200V, I=25A) causing disadvantageous
distribution of the stretching stresses in the surface layer.
The optimal electrical parameters (current voltage and
intensity) have been determined assuring advantageous
distribution of the internal stresses during AEDG process.
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