Observing the latest manufacturing processes, the following tendencies can be noted: the gain of the energetic efficiency and shortening of the processing time with parallel preservation of the dimensions tolerance, shape tolerance and outer layer quality of the processed workpiece. Also the possibilities of gaining efficiency by rising criteria for process parameters are limited. It is mainly observed in the processing of hard machinable materials like titanium alloys or sintered carbides. Problems related to poor machinability were revealed during the final manufacturing processes using abrasive grinding [1,2]. In this work the results which have been presented are related to the influence by selected electrical parameters of the Abrasive Electrodischarge Grinding (AEDG) on the surface layer temperature of machined samples, in comparison to conventional grinding. Also the change in temperature during the AEDG has been depicted. The basis of this work is similar to the investigations of the deep grinding of surfaces of the titanium alloy Ti6Al4V using CBN and a diamond grinding wheel. For the comparative evaluation of the conventional grinding and AEDG, measurements of the specific grinding energy, energy of the spark discharge and internal stresses in the surface layer have been used.

The heat generation process during the abrasive electrodischarge grinding (AEDG) process is one of the most critical sub processes, sometimes settling the critical issue. Thus the need for precise evaluation of this process which can be done in different ways, exemplary with using the infrared (IR) camera, which in turn seems to be flexible and comfortable in use. But precise and reliable measurement with using an infrared camera is not so straightforward due to the problem of camera calibration. Even for relative expensive equipment of this kind, the self‐calibration is performed in a way which is not fully adequate for precise measurement. Here we propose to apply a precisely heated etalon as radiation temperature standard. The whole method is based upon comparison of two independent measurements, one of them treated as the reference standard due to the high precision and reliability of the thermocouple measurements. This comparison, accomplished with the strong help of numerical procedures, is performed between two surfaces, not points like during bolometric‐like measurements, taking into account specific generation of the thermal picture with using focal plane array (FPA) infrared sensor.

Titanium and its alloys are widely recognized as the hardly machinable materials, especially due to their relatively high hardness, low thermal conductivity and possible subcritical superplasticity. Then, a thorough control of the machining process parameters shall be maintained. In this paper, we have concentrated on the grinding of the Ti6Al4V titanium alloy using cBN (boron nitride) grinding wheel combined with the AEDG (abrasive electrodischarge grinding) process. The mathematical model we have dealt with has been based mainly on Jaeger model of the heat taking over between sliding bodies with substantial upgrades related to:• estimation of the frictional heat generating based on friction forces distribution, • spatial, not only planar, shape of the contact area, • generated heat partition between different parties of the grinding process, • heat transfer in the multilayered environment.The experimental verification of the theoretical predictions has been carried out. Fundamental difficulty in such a research is placing temperature probes sufficiently close to the ground surface with possibly low space devoted for probes due to the temperature field deformation with relation to the real conditions of grinding. The temperature field in the machined workpiece has been investigated using electronic data logging and DSP methods. Obtained results exhibit clearly that distribution of heat generation in the contact zone could be of the relatively complicated shape due to the external cooling and the very specific heat transfer and accumulation in the titanium workpiece surface layer.

Widely used in mechanics is the method of surface parameters investigation by indentation of some kind of penetrator into test surfaces and registration of the indentation/load dependence through the whole test duration. A small ball made of hardened steel or diamond pyramid, so-called Berkovich pyramid, is used for penetration. An actuator performing the indentation process is used for displacement enforcement as well as for load measurement. Mainly two types of devices are in use: based on piezoelectric effect or purely electromagnetic LVDT. Knowledge about the penetrator tip is essential for the proper evaluation of the measured parameters and knowledge about the actuation method is also desired for better identification of the whole system parameters when using DSP type algorithms at the stage of experimental data elaboration. In this paper we deal with some kind of DSP elaboration of the experimental data. Our attitude is based on successive digital filtration applied to the experimental data as well as to the intermediate stages of calculation, especially for compliance estimation. Different digital filters have been developed and applied to the experimental data. Some conclusions have been taken out due to the precision of the layer thickness estimation based on data obtained by indentation of the investigated surface with a Berkovich pyramid driven by a piezoelectric actuator. The Boussinesq/Sneddon theory has been used as the basis of our analysis. Titanium azide layers imposed on a magnesium alloy have been tested using PVD method. Obtained results especially due to the hardness/indentation plot allow evaluating the layer thickness, which should be also compared with thickness values evaluated by other methods.

In the paper a new method has been proposed for the determining of the very fine machining uniformity over the elaborated surface and could be applied to different machined materials and machining procedures. The proposed methodology is relatively simple and is essentially formulated in the few subsequent steps: taking surface roughness 3D profile accordingly proposed scheme; estimation of the roughness statistical parameters: Rp, Rv, Rt, Ra, Rq, Rskew, Rkurt, and if need be – surface rugosity Ru; calculation of the centroid of the obtained data due to the measurement fields, calculation of the barycentre of the obtained data with the weighting variable chosen for the appropriate evaluation of the surface machining uniformity. As the main Cartesian coordinates of the centroid calculation we propose (Rskew, Rkurt), although other data organization schemes have also been provided as the example solutions. The final evaluation of the surface machining uniformity is based upon the Euclidean distance between the centroid and barycentre of the surface roughness data. The proposed method has been applied to experimental results obtained with the AFM technique used on samples of the polished AZ31 magnesium alloy. The surface machining procedure comprised of four stages performed with using different abrasive media, finally lead to the highest grade of the surface roughness.