OBRABOTKAMETALLOV Vol. 28 No. 2 2026 132 EQUIPMENT. INSTRUMENTS Formation of the cutting relief of a metal-bonded diamond wheel through continuous electrochemical dressing in combined electro-diamond grinding of composite materials: toward the development of hybrid machine tool equipment Vadim Skeeba 1, a, *, Andrey Yanyushkin 2, b, Dmitry Lobanov 2, c, Alexander Yanyushkin 2, d, Alexey Chernikov 1, e, Maria Yavorskaya 1, f, Alexander Nasonov 1, g 1 Novosibirsk State Technical University, 20 Prospekt K. Marksa, Novosibirsk, 630073, Russian Federation 2 I.N. Ulianov Chuvash State University, 15 Moskovsky Prospekt, Cheboksary, 428015, Russian Federation a https://orcid.org/0000-0002-8242-2295, skeeba_vadim@mail.ru; b https://orcid.org/0000-0002-5744-8987, andreyyanyushkin@gmail.com; c https://orcid.org/0000-0002-4273-5107, lobanovdv@list.ru; d https://orcid.org/0000-0003-1969-7840, yanyushkinas@mail.ru; e https://orcid.org/0009-0006-9412-7687, aleksey.chernikov.97@mail.ru; f https://orcid.org/0000-0002-2449-8638, ivanova777888@yandex.ru; g https://orcid.org/0009-0001-3177-0732, a.nasonov@corp.nstu.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2026 vol. 28 no. 2 pp. 119–135 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2026-28.2-119-135 ART I CLE I NFO Article history: Received: 27 February 2026 Revised: 16 March 2026 Accepted: 21 March 2026 Available online: 15 June 2026 Keywords: Metal-bonded diamond wheel Combined electro-diamond grinding Continuous electrochemical dressing Composite materials Cutting ability Oxide fi lms Hybrid machine tool equipment Anodic dissolution of stock allowance Funding This work was supported by the Ministry of Science and Higher Education of the Russian Federation (project FSUN-20260005). ABSTRACT Introduction. One of the key trends in modern mechanical engineering is the development of hybrid machine tool equipment that integrates mechanical and surface-thermal technological operations within a single machine platform. In the context of the Industry 4.0 paradigm and increasing demands for precision, productivity, and equipment multifunctionality, combined electrodiamond grinding (CEDG) – which combines mechanical cutting by diamond grains with electrochemical action on both the tool and the workpiece – is of particular relevance. Grinding of high-strength composite materials based on zirconium diboride (ZrB₂) under conventional conditions leads to intensive clogging of metal-bonded diamond wheels and a critical loss of their cutting ability, rendering the conventional process ineffi cient. Despite existing results in the fi eld of electro-diamond machining, the issues of stageby-stage formation of the cutting relief on the wheel working surface under continuous electrochemical dressing, the mechanisms of oxide fi lm formation on bond elements, and their functional role as solid lubricants in the contact zone remain insuffi ciently studied. The purpose of this work is to establish the formation mechanisms of the surface layer of a metal-bonded diamond wheel under continuous electrochemical dressing with simultaneous electrochemical anodic dissolution of the stock allowance during combined grinding of a ZrB₂-based composite material, and to substantiate the prospects for integrating this technology into the concept of hybrid machine tool equipment. Methods. Experiments were conducted on a modernized PP-600F surface grinding machine equipped with two independent electrical circuits: a continuous electrochemical dressing circuit (current density 0.1–0.6 A/ cm2) and an anodic dissolution circuit for stock removal (current density 15–30A/cm2). Diamond wheels AC6 125/100 M1 – 100% on a copper-zinc-aluminum bond were used as the tool. The working medium was a nitrite-nitrate electrolyte (3% NaNO3, 1% NaNO2, 0.5% Na2CO3). Mechanical parameters: cutting speed 35 m/s, longitudinal feed 0.5–2.5 m/min, depth of cut 0.01–0.04 mm. Surface topography of the wheel and workpiece was investigated by scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS). Results and Discussion. It is established that continuous electrochemical dressing ensures selective anodic dissolution of the metal bond components (primarily aluminum, copper, and zinc), forming a stable cutting relief with exposed diamond grains and intergranular cavities for electrolyte and debris accommodation. It is shown that under simultaneous operation of the dressing and workpiece etching circuits, oxide fi lms form on the diamond grain surfaces and bond elements, functioning as solid lubricants and reducing the intensity of adhesion-diff usion interaction in the contact zone. Implementation of additional electrochemical weakening of the stock allowance reduces cutting forces and contact temperatures, preventing deformation damage to the workpiece surface layer. It is substantiated that the developed CEDG technology constitutes a technological basis for designing hybrid machine tool equipment integrating mechanical and electrochemical actions, meeting modern requirements for modularity, adaptability, and digital control. The obtained results contribute to the formation of a theoretical and methodological framework for designing next-generation hybrid metalworking systems. For citation: Skeeba V.Yu., Yanyushkin A.R., Lobanov D.V., Yanyushkin A.S., Chernikov A.D., Yavorskaya M.V., Nasonov A.I. Formation of the cutting relief of a metal-bonded diamond wheel through continuous electrochemical dressing in combined electro-diamond grinding of composite materials: toward the development of hybrid machine tool equipment. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2026, vol. 28, no. 2, pp. 119–135. DOI: 10.17212/1994-6309-2026-28.2-119-135. (In Russian). ______ * Corresponding author Skeeba Vadim Yu., Ph.D. (Engineering), Associate Professor, Leading researcher Novosibirsk State Technical University, 20 Prospekt K. Marksa, Novosibirsk, 630073, Russian Federation Tel: +7 383 346-17-79, e-mail: skeeba_vadim@mail.ru
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