Investigation of Wire EDM Dressing of Metal-Bond Diamond Grinding Wheels and Its Impact on Grinding Performance

Grinding wheel conditioning is critical for maintaining cutting efficiency and surface quality, yet conventional mechanical dressers struggle with metal-bonded superabrasive wheels. In this study, wire electrical discharge machining (WEDM) dressing was evaluated on metal-bond diamond wheels of two grit sizes (D54 and D91) and compared to standard mechanical dressing. Dressing was performed on a WEDM machine using varied discharge currents, open-circuit voltages, and duty factors; subsequently, each wheel ground twelve grooves in tungsten carbide under identical parameters. Performance was assessed via maximum spindle power, tangential and normal forces, surface roughness (Ra), radial wheel wear, and edge radius. WEDM-dressed wheels exhibited up to 56% lower peak spindle power and 40–50% lower forces than mechanically dressed wheels. Compared to mechanically dressed wheels, WEDM-conditioned wheels exhibited markedly lower radial wear and maintained substantially sharper, more stable edge radii throughout the grinding cycles. Surface roughness converged after an initial break-in, matching mechanical methods. By selectively eroding the bond without damaging grains, WEDM dressing extends dressing intervals by approximately fivefold and reduces maintenance.