Mechanism study on ultrasonic vibration assisted face grinding of Hard and brittle materials

Abstract

Ultrasonic vibration assisted face grinding (UAFG) has excellent performance in hard and brittle materials processing. In order to reveal the surface generating mechanism and improve the machining quality, this study was dealing with investigation on ultrasonic energy distribution and surface generating characteristics. Based on the modeling of grinding force, surface generation and material removal volume, the grinding mechanism of UAFG is analyzed and presented in detail. The surface generating process is described by grain trajectory interference and overlap, and the grinding force model is established based on fracture mechanics of brittle materials. According to the mathematical modeling, an innovation for surface adjustment and grinding force calculation in UAFG is proposed. Depend on the theoretical study, the combined effect of ultrasonic vibration and processing parameters on grinding force and surface micro structure in UAFG is reported. The surface characteristics can be designed and simulated by process parameter optimization; high performance surface can be achieved due to the theoretical calculation. The correctness of the theoretical derivation is verified by numerical calculation and comparative experiments. This investigation can be used as a basic principle for machining surface improvement and processing technology modification in UAFG.