On-Machine Precision Truing and Error Compensation of Cup-Shaped Diamond Grinding Wheels with Arc-Shaped Cutting Edge

The cup-shaped grinding wheels with arc-shaped edges provide a satisfactory precision grinding solution for high-accuracy optical surfaces on hard and brittle materials. However, the complex profile of the arc-shaped edges of cup-shaped grinding wheels makes them challenging to truing. This paper proposes an on-machine truing technique targeting cup-shaped grinding wheels with arc-shaped cutting edge. First, a mathematical model was established to simulate the three-axis of on-machine truing the arc-shaped cutting edge using a diamond roller. Based on this model, a theoretical analysis is conducted to investigate the impact of tool setting errors, measurement errors of the diamond roller, and the pose error on truing accuracy. A compensation method was proposed, and experimental results validated its effectiveness. To investigate the grinding performance of cup-shaped grinding wheels after truing, a complex component is ground using a truing diamond grinding wheel. The experimental results demonstrate that this method enables precise on-machine truing of the arc-shaped edges of cup-shaped grinding wheels and is efficient. The average dimensional accuracy of the grinding wheel's arc-shaped edge is reduced to 1.5 μm, with the profile accuracy (PV) of 0.89 μm.