The effects of electrolytic grinding on surface conditions and residual stress characteristics has been experimentally investigated. Surface finish, uniformity of material removal, and corrosion resistance are found to be dependent on mechanical removal rate as determined by wheel downfeed as well as electrolyte flow rate. Downfeeds of approximately 0.002 in. in the process do not produce measurable residual stresses and therefore it was further established that electrolytic grinding with moderate downfeeds can be used in place of swab etching techniques for evaluation of residual stress distributions. The maximum residual surface stresses were found to be not more than 22,000 psi, well below the yield strength of the material and were induced during the most severe grinding conditions.

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