Modelling of surface texture and parameters matching considering the interaction of multiple rotation cycles in ultrasonic assisted grinding

Abstract

In comparison with ordinary grinding (OG), ultrasonic assisted grinding (UAG) yields unique texture structure and better surface quality. Considerable research effort has been devoted to the investigation of the relationship between UAG parameters and surface roughness. However, the quantitative description of the matching relationship of UAG parameters and its effect on surface micro-topography (surface texture structure and roughness) is still a subject little investigated by the scientific community. In this paper, a novel parameter called matching phase difference (MPD) was proposed to quantitatively characterize the matching relationship between the ultrasonic and grinding parameters based on the interaction effect of multiple wheel rotation cycles. A comprehensive analytical model of MPD and surface micro-topography (surface texture and surface roughness) was developed. The experimental results and theoretical analysis both showed that the MPD could well characterize the matching relationship between the ultrasonic and grinding parameters. Then, the optimal UAG parameters for surface roughness and texture patterns was further studied based on the analytical model. The novel model proposed in this paper sheds new light on surface micro-topography in UAG, which is conducive to get a better insight into the material removal mechanism and the development of industrial applications of UAG.