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<p>This study investigates the effects of electrical discharge assisted grinding (EDAG) by establishing a heat source model based on heat conduction theory and Gaussian distribution principles. The model incorporates the energy generation mechanism of electrical discharge machining (EDM) and discharge channel equations. Thermodynamic simulations of EDAG were conducted alongside experimental validation.At low rotational speeds, the grinding depths of the cathode and anode grinding wheels exhibited left-right asymmetry, with the anode rod’s grinding depth significantly deeper than that of the cathode rod. Increasing the current enhanced the number and density of electrical discharge ablation craters on the surface microtopography, and the material removal rate (MRR) waveform converged toward specific positions. In the experiments, current parameters adjusted the proportion of electrical discharge ablation in EDAG by regulating the discharge gap and EDM pulse intensity. Increasing the spindle speed effectively improved surface flatness, while increasing the grit size of the grinding wheel refined the grinding marks on the workpiece surface and enhanced surface finish. At a rotational speed of 1500&#xa0;rpm, the MRR achievement rate was inversely proportional to the grit size of the grinding wheel. The 300-grit anode grinding wheel achieved the highest achievement rate of 84.56% under the conditions of 2500&#xa0;rpm and 8&#xa0;A, with the smallest difference between the theoretical MRR and actual MRR, measuring only 0.001141&#xa0;mm³/s.</p>

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Thermo-mechanical coupling formation mechanism and experimental characterization of 3D surface topography in electrical discharge assisted grinding

  • 期刊论文

  • 发表日期：

    2026年4月11日

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  • Yinghuai Dong,
  • Zimo Fu,
  • Jindong Xin,
  • Wen Zhou,
  • Yan Wang,
  • Pengyu Song

摘要

This study investigates the effects of electrical discharge assisted grinding (EDAG) by establishing a heat source model based on heat conduction theory and Gaussian distribution principles. The model incorporates the energy generation mechanism of electrical discharge machining (EDM) and discharge channel equations. Thermodynamic simulations of EDAG were conducted alongside experimental validation.At low rotational speeds, the grinding depths of the cathode and anode grinding wheels exhibited left-right asymmetry, with the anode rod’s grinding depth significantly deeper than that of the cathode rod. Increasing the current enhanced the number and density of electrical discharge ablation craters on the surface microtopography, and the material removal rate (MRR) waveform converged toward specific positions. In the experiments, current parameters adjusted the proportion of electrical discharge ablation in EDAG by regulating the discharge gap and EDM pulse intensity. Increasing the spindle speed effectively improved surface flatness, while increasing the grit size of the grinding wheel refined the grinding marks on the workpiece surface and enhanced surface finish. At a rotational speed of 1500 rpm, the MRR achievement rate was inversely proportional to the grit size of the grinding wheel. The 300-grit anode grinding wheel achieved the highest achievement rate of 84.56% under the conditions of 2500 rpm and 8 A, with the smallest difference between the theoretical MRR and actual MRR, measuring only 0.001141 mm³/s.