«Modeling the interaction of a tool with a part during EDM grinding with variable polarity of electrodes in the cutting zone»

Abstract

The contact area is the area of mutual penetration of the cutting edges into the workpiece
material and the protrusions of the materials into the gaps between the grains. The parameters of the
state of the zone include its size and shape, the ratio of the removed and not removed parts of the
metal in each area of the zone, physical processes of shaping, including chip formation, heat release, plastic deformation of the processed material, wear and destruction of tool material,
physical and chemical effects of lubricating and cooling liquid on materials.
The output variables of the zone include cutting forces, heat flow parameters, fields of
cutting surfaces and fields of secondary processes, wear rate of abrasive material, and a number of
other variables.
Distribution of heat fluxes, physical and mechanical properties of the processed and tool
materials in the contact zone.
The article examines the analysis of the patterns of material removal, work and destruction,
single abrasive grains. The solution of these issues in combination with the dependencies known
from the literature made it possible to consider the balance of displacements in the technological
system, develop dynamic models of material removal and tool wear, and clarify the existing
methods for the analytical calculation of surface roughness and shape accuracy.
The form of the obtained ratios directly shows that a significant part of the chips formed by
the cutting edges in contact with the rough surface of the workpiece are short and do not collide
with the binder to tear off from the workpiece body even without taking into account their
shrinkage.
The obtained ratios can also be used in solving the corresponding problems of grinding with
the periphery of a wheel, for example, circular grinding. With a clearer description of the process, it
is necessary to directly apply the non-stationary representation, taking into account the additional
non-stationary ones introduced by the trajectories of the cutting edges as a function of the angle of
rotation of the circle and the part in the process of their interaction.