OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 7 No. 1 2025 At the final stage of the technological process of machining, it is necessary to minimize the force and heat generation in the contact zone between the workpiece and the abrasive tool in order to achieve the required quality of the processed surfaces. Such requirements impose restrictions on the choice of finishing methods and conditions. Process efficiency is significantly increased when using combined, or hybrid, methods to affect the surface being processed [1‑19]. When machining complex shaped parts, increased attention is given to finishing operations, particularly to reducing roughness while maintaining previously achieved dimensional accuracy indicators. For this purpose, rigid-base abrasive tools (abrasive heads on a metal bond) are often used and integrated into a less rigid technological system are often used, and integrated into a less rigid technological system. The tool can be edited electrochemically, continuously with the use of an additional electrical circuit or intermittently without its use. Feed alternating with a certain interval of reverse polarity current pulses is made directly to the operating circuit. To increase the efficiency of the process, it is necessary to establish optimal modes of mechanical and electrochemical processing of parts [20‑27]. If there is no possibility to use industrial equipment for hybrid technologies at the initial stage, and considering the need to modernize existing technological equipment for performing the electrochemical grinding process, it is advisable to study this process by modelling it on simulators [28‑31]. The aim of the work is to develop a device to study and simulate the process of electrochemical grinding of conductive parts with abrasive heads on a metal bond. To achieve this goal, the following tasks were formulated: 1) to identify, based on modeling, the operating parameters of the system under study and the applicability of the device for studying the roughness of processed parts in the process of electrochemical grinding with abrasive heads on a metal bond. 2) to conduct empirical studies of the roughness of the processed surfaces depending on the modes of electrochemical grinding. 3) to substantiate the possibility of using the developed device to study the process of electrochemical grinding of conductive parts with abrasive heads on a metal bond. Methods To simulate the process of electrochemical grinding of conductive parts with abrasive heads on a metal bond, a special device was developed. The block diagram of this device is shown in Fig. 1. The proposed device allows positioning theworkpiece and tool, implement the process of electrochemical grinding, its kinematic and electrical conditions: the primary motion, linear motion of working elements, mechanical and electrical modes, provide the necessary conditions for the implementation of the technology (electrolyte and its supply to the processing zone), and implement a control system. To determine the model of the engraver that gives the rotary motion of the abrasive head and the drive for linear motion of the abrasive head, the cutting forces and cutting power were calculated. The abrasive grinding modes were selected in accordance with the modes used in the study of hybrid technology for electrochemical processing of 0.12C-18Cr-10Ni-Ti stainless steel with a diamond cylindrical head with a working part diameter of 3 mm and a shank diameter of 2 mm. Cutting speed ranged from 4.7 m/s to 6.05 m/s, cutting depth from 0.04 mm to 0.06 mm, longitudinal feed rate from 230 mm/min to 250 mm/min [32]. As a result, the maximum cutting power values of 0.128 kW were obtained. Tool deformation calculations were performed additionally using the ANSYS software. The model with boundary conditions for the study is shown in Fig. 2. Table 1 shows the calculation examples. The tool deformation ranged from 0.14 to 0.23 mm. Fig. 3 shows a general view of the linear drive of the working body. It serves to provide a longitudinal feed of the tool and consists of a DC motor, a screw-nut transmission, and a slider. Table 2 shows the technical characteristics of the linear drive. The Zubr ZG-160EK engraver is used to give the main cutting motion to the abrasive head. Technical characteristics of the engraver Zubr ZG-160EK are given in Table 3.
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