Prediction modelling of cutting force in rotary ultrasonic end grinding 2.5D woven SiO2f/SiO2 ceramic matrix composite

Abstract

Rotary ultrasonic end grinding (RUEG) of ceramic matrix composites has advantages in reducing sub-surface damages and improving machined surface quality. The cutting force prediction for RUEG can reveal the mechanic information and machined surface quality in the grinding process. However, the prediction model for grinding force in RUEG of SiO2f/SiO2 ceramic matrix composite has not been reported in literatures. In this paper, the mechanical properties of 2.5D woven SiO2f/SiO2 ceramic matrix composite are estimated using stiffness averaging method. Furthermore, the theoretical prediction model for axial and transverse grinding force component in RUEG of 2.5D SiO2f/SiO2 composite is developed. The development of the prediction model is based on the analysis of a single abrasive grit on the grinding wheel end and side face, including kinematic analysis, penetration depth, and effective machining time in RUEG. The final axial and transverse grinding force component is predicted by considering the force contributions of all end and side abrasive grits involved in RUEG, respectively. The prediction results of the developed model are validated by experimental results. The influence mechanism of process parameters on the axial and transverse grinding force component in RUEG of 2.5D SiO2f/SiO2 composite is explained by the developed prediction model.