Study on key factors influencing the surface generation in rotary ultrasonic grinding for hard and brittle materials

Abstract

Rotary ultrasonic grinding (RUG) provides effective solutions for hard and brittle materials processing, but the surface generating mechanism is still unclear. This paper presented a fundamental research for surface forming in RUG processing hard and brittle materials. A new method is pointed out for surface morphology regulating and predicting in engineering ceramics machining. According to the kinematics analysis and fracture mechanics of brittle materials, the surface forming model is developed step by step. The grinding force and material removal rate are discussed for evaluated the RUG process. Depend on the mathematical models, the dynamic association between ultrasonic energy, grinding parameters and surface micro structure were revealed and presented. The surface topography can be simulated and regulated by ultrasonic energy control or grinding parameters adjustment. Micro structure design and high precision machined surface can be realized through theory calculation. Due to the fundamental analysis, a series of simulation and experiment were executed for verify the theory deduction. This model can be served as a fundamental principle for surface topography modification and machining efficiency improvement in RUG.