Profile Prediction and Analysis in Active Controlled Elastic Emission Machining

In this study, EEM with active gap control (ACEEM) was developed, controlling the fluid film thickness as the sum of the initial polishing gap and the polishing wheel deformation, thereby making it feasible to predict the material removal profile. By analyzing the hydrodynamic lubrication state in the polishing region, a material removal profile prediction model was constructed. The material removal process is decomposed into the individual effects of pressure and shear stress, with consideration given to energy threshold caused by chemical reaction. The model was applied to different materials and process parameters, demonstrating commendable accuracy and robustness. In addition, the model reveals the shear stress plays a leading role in the material removal process. Finally, the dwell time was calculated based on the model, achieving deterministic machining of a hyperboloid on a plane. The surface roughness is improved from 0.553 nm root mean square (RMS) to 0.085 nm RMS. This proves that ACEEM can improve surface roughness while converge the surface shape.