Nano-level surface generation on H13 alloy steel by ultra-precision grinding with electrolytic in-process dressing

The aim of this work was to achieve the surface finish of 10nm on a 40mm diameter disc of chrome-molybdenum-vanadium alloyed steel (H13) by using precision grinding process with electrolytic in-process dressing. The machine tool utilized was Tetraform-C, its unique tetrahedral frame offered higher structural stability. A cup grinding wheel with iron bonded CBN abrasive grit of 76 microns average size with 50% concentration was used. The statistical methods were employed to determine the optimal combination of input parameters to achieve the required response. The main effect of feed rate was found to be more significant than the depth of cut and lower levels of these factors produced better surface finish. The developed regression model based on the relationships between process variables was used to predict factor levels to achieve the required process response.