The cylindrical wire EDM truing of the metal bond diamond wheels for form grinding of ceramics and the material removal rate in wire EDM of diamond wheel are presented. The wire EDM process uses the thermal energy or electrical sparks between the wire and rotating grinding wheel to remove the metal bond and form the diamond wheel. The design of a corrosion-resistant, precise spindle for wire EDM truing of grinding wheel is first introduced. Three truing configurations were designed to study the adjustment of wire EDM process parameters and to investigate the level of form accuracy and corner radii achievable by the wire EDM truing of diamond wheels. Results show that the wire EDM process can efficiently generate the μm-scale precision form on the diamond wheels. The wheel, after truing, was used to grind the silicon nitride workpiece. Grinding forces and wheel wear rate were measured. In the beginning of the grinding, high wheel wear rate was identified. The subsequent wheel wear rate was considerably lower and stabilized. This wear mechanism is studied using the stereo SEM.
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