Feasibility of Ultrasonic Vibration Assisted Grinding for Carbon Fiber Reinforced Polymer with Monolayer Brazed Grinding Tools

Abstract

Ultrasonic vibration assisted grinding (UVAG) is an effective method for edge trimming to improve the mechanical integrity of carbon fiber reinforced polymer (CFRP). However, due to the high heat resistance, abrasiveness and powdery chip of CFRP, serious tool clogging, rapid tool wear and poor surface are still considerable problems to the industry. In this paper, monolayer brazed diamond grinding tools with defined grain distribution are designed in order to solve the above problems. The maximum undeformed chip thickness based on UVAG was analyzed. A mathematical grinding force model was established based on monolayer brazed diamond tools. The UVAG experiments using different grain inter-row spacing diamond tools were carried out. The grinding force and surface morphology were investigated and compared. It was found that the predicted grinding force values were consistent with the experimental results. Additionally, the force was strongly related to the grain inter-row spacing. When employing the tool with the grain inter-row spacing of 1.2 mm, the grinding force was highest and the roughness of the surface was better due to more active grits and interaction-overlap areas.