Optimization of the Diamond Roller Dressing Parameters of Grinding Wheels to Improve the Ground Surface Quality

The quality of ground surfaces depends largely on the topography of the active surface of the grinding wheel, which, in turn, is determined both by the structure of the grinding wheel and by the conditions of the dressing process. This article proposes a new approach to improving the quality of ground surfaces by optimizing the dressing conditions with diamond rollers, based on the correlation between the roughness of the ground surfaces, the roughness of the cutting surface of the grinding wheel, and the parameters of the dressing process. A comprehensive theoretical–experimental study and modeling of the microgeometry of electrocorundum grinding wheels and the roughness of ground surfaces, depending on the dressing conditions with diamond dressing rolls made of medium- and high-strength synthetic diamonds with a mixed grit size, has been carried out. A complex quality indicator has been defined, determined as the ratio between the roughness of the ground surfaces and the roughness of the cutting surface of the grinding wheels, and models have been constructed for its determination, depending on the dressing conditions. By applying a genetic algorithm, optimal conditions for uni-directional and counter-directional dressing (dressing speed ratio, radial feed rate, the dress-out time and the ratio between the grit sizes of the diamond roller dresser and grinding wheel) have been determined, which ensure a minimum value of the complex quality indicator in combination with minimum roughness of the ground surfaces.