Modeling of oxide-film thickness in electrolytic in-process dressing grinding with workpiece swing

This paper proposes a modeling method for oxide-film thickness to determine the quantitative relationship between the current and oxide-film thickness in electrolytic in-process dressing (ELID) grinding with workpiece swing. Using this method, the generation thickness of the oxide film per unit time was calculated based on Faraday’s law. The oxide-film thickness was calculated using current integration to determine the quantitative relationship between current and oxide-film thickness. Based on the ELID grinding experiment with workpiece swing, the influence of different swing parameters on the oxide-film thickness was analyzed, and the formation mechanism of the oxide film was obtained. The calculation results indicated that as the current decreased from 2.96 to 0.17 A, the oxide-film thickness increased from 0 to 52.79 μm. The experimental results indicated that as the swing amplitude increased from 10° to 30°, the current increased from 1.45 to 2.51 A, and the oxide-film thickness decreased from 33.89 to 24.58 μm. As the swing angular velocity increased from 5 to 15°/s, the current increased from 1.42 to 2.33 A, and the oxide-film thickness decreased from 34.15 to 26.68 μm. Elucidation of the oxide-film formation mechanism can provide a theoretical basis for improving the surface quality of arc grooves.