Abstract
<jats:p>Introduction. One of the key trends in modern mechanical engineering is the development of hybrid machine tool equipment that integrates mechanical and surface-thermal technological operations within a single machine platform. In the context of the Industry 4.0 paradigm and increasing demands for precision, productivity, and equipment multifunctionality, combined electro-diamond grinding (CEDG) – which combines mechanical cutting by diamond grains with electrochemical action on both the tool and the workpiece – is of particular relevance. Grinding of high-strength composite materials based on zirconium diboride (ZrB₂) under conventional conditions leads to intensive clogging of metal-bonded diamond wheels and a critical loss of their cutting ability, rendering the conventional process inefficient. Despite existing results in the field of electro-diamond machining, the issues of stage-by-stage formation of the cutting relief on the wheel working surface under continuous electrochemical dressing, the mechanisms of oxide film formation on bond elements, and their functional role as solid lubricants in the contact zone remain insufficiently studied. The purpose of this work is to establish the formation mechanisms of the surface layer of a metal-bonded diamond wheel under continuous electrochemical dressing with simultaneous electrochemical anodic dissolution of the stock allowance during combined grinding of a ZrB₂-based composite material, and to substantiate the prospects for integrating this technology into the concept of hybrid machine tool equipment. Methods. Experiments were conducted on a modernized PP-600F surface grinding machine equipped with two independent electrical circuits: a continuous electrochemical dressing circuit (current density 0.1–0.6 A/cm2) and an anodic dissolution circuit for stock removal (current density 15–30 A/cm2). Diamond wheels AC6 125/100 M1 – 100% on a copper zinc aluminum bond were used as the tool. The working medium was a nitrite nitrate electrolyte (3% NaNO3, 1% NaNO2, 0.5% Na2CO3). Mechanical parameters: cutting speed 35 m/s, longitudinal feed 0.5–2.5 m/min, depth of cut 0.01–0.04 mm. Surface topography of the wheel and workpiece was investigated by scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS). Results and Discussion. It is established that continuous electrochemical dressing ensures selective anodic dissolution of the metal bond components (primarily aluminum, copper, and zinc), forming a stable cutting relief with exposed diamond grains and intergranular cavities for electrolyte and debris accommodation. It is shown that under simultaneous operation of the dressing and workpiece etching circuits, oxide films form on the diamond grain surfaces and bond elements, functioning as solid lubricants and reducing the intensity of adhesion diffusion interaction in the contact zone. Implementation of additional electrochemical weakening of the stock allowance reduces cutting forces and contact temperatures, preventing deformation damage to the workpiece surface layer. It is substantiated that the developed CEDG technology constitutes a technological basis for designing hybrid machine tool equipment integrating mechanical and electrochemical actions, meeting modern requirements for modularity, adaptability, and digital control. The obtained results contribute to the formation of a theoretical and methodological framework for designing next generation hybrid metalworking systems.</jats:p>