Surface finish and chip formation resulting from electrolytic in-process grinding

Electrolytic in-process grinding (ELID) is an ultraprecision process in mirror-like surface finish; it can be applied to hard brittle and ductile materials. Unlike the normal grinding process, various mechanism of repeated crush, shearing, dislocation and slip by micro abrasive take place in ELID. Chip on the workpiece surface is formed as a result of plastic damage accumulation. A mechanics model is developed in analyzing the phenomenon of microchip formation; it can be applied to examine the process of ultraprecision grinding as well as lapping and polishing.