The grinding force modeling and experimental study of ZrO2 ceramic materials in ultrasonic vibration assisted grinding

Abstract

As an advanced structural ceramic, zirconia ceramics are gradually used in the fields of manufacturing, aerospace and other fields with their excellent properties. However, the mechanism of material removal is complex for zirconia ceramics but it is generally accepted that the brittle-and-hard material is removed by plastic removal and brittle removal. In this paper, ultrasonic vibration assisted grinding is used as non-traditional processing to machine the ceramic materials. Firstly, a single abrasive grain scratch test was first carried out on the ZrO2 ceramic materials. It can be obtained through experimental analysis that the removal mode of the zirconia ceramic material is changed with the increase of load. When the applied load is greater than 500 mN, the zirconia ceramic materials are removed by brittle removal. Then, based on analysis of scratch test and kinematics of ultrasonic vibration assisted grinding (UVAG), a grinding force prediction model is developed and the validity of the model is verified by the experiment designed. It can be found that the grinding force is decreased with the increase of spindle speed (n) and amplitude (Aa). And the grinding force is increased with the increase of feed rate (vf) and grinding depth (ap). In addition, compared with the grinding force of the common grinding (CG), the grinding force is significantly reduced in the UVAG. And the surface quality of the workpiece is improved and the wear of the grinding head is reduced in the UVAG by the analysis of experiment.