Monitoring of ductile–brittle transition mechanisms in sapphire ultra-precision grinding used small grit size grinding wheel through force and acoustic emission signals

Abstract

Progressive ultra-precision grinding experiments used small grit size grinding wheels were performed to investigate the ductile–brittle transition process of sapphire, force and AE signals were employed to monitor the material removal behavior. Precision dressing and measurement of circular arc grinding wheels were performed to meet the minimum grinding depth for ultra-precision grinding. A grinding force model was proposed to interpret the grinding forces in different materials removal modes. A continuous complete ductile–brittle transition process was observed and monitored, the progressive grinding was divided into three stages: ductile dominant, ductile–brittle transition and brittle eruption. The grinding force, surface profile, micro morphology and brittle fracture percentage were discussed. Brittle fracture will not entirely occur, but rather brittle fracture and ductile grooves were coexisted on the surface in the brittle eruption stage, which was attributed to the grinding characteristics of small grit wheels. In addition, raw AE signals and multiple transformation forms were utilized to monitor the material removal behavior and their respective roles were analyzed. The Fourier transform, discrete wavelet, continuous wavelet and wavelet coefficients in different stages can all establish a mapping relationship with material removal modes.