Research on Ultrasonic Vibration Grinding of the Hard and Brittle Materials

It is well known that grinding techniques are main methods to machine hard and brittle materials such as engineering ceramics. But the conventional grinding has many shortcomings such as poorer surface finish, quicker wear and tear of grinding tools, lower efficiency and so on. Ultrasonic vibration grinding （UVG） which combines ultrasonic machining and grinding emerged as a developing and promising technique in recent years. In this paper, experimental studies on UVG were conducted on several kinds of hard and brittle material by altering processing parameters such as vibration frequency and its amplitude, diamond abrasive grit size, cutting depth, feeding speed and rotary speed of tools. The experimental results show that alteration in any of above mentioned parameters will bring effects on the processed surface finish of these materials. Of them, the diamond abrasive grit size has the greatest. Moreover, conventional grinding experiments were also carried out on these materials. By comparison, it was found that the UVG is superior to the conventional method in terms of the ground surface quality, the working efficiency and the wear rate of tools.

Surface Topography of Fine-grained ZrO_2 Ceramic by Two-dimensional Ultrasonic Vibration Grinding

The surface quality of fine-grained ZrO2 engineering ceramic were researched using 270# diamond wheel both with and without work-piece two-dimension ultrasonic vibration grinding（WTDUVG）. By AFM images, the surface topography and the micro structure of the two-dimensional ultrasonic vibration grinding ceramics were especially analyzed. The experimental results indicate that the surface roughness is related to grinding vibration mode and the material removal mechanism. Surface quality of WTDUVG is superior to that of conventional grinding, and it is easy for two-dimensional ultrasonic vibration grinding that material removal mechanism is ductile mode grinding.

Experimental Studies on Ultrasonic Vibration Grinding of the Workpiece Made from Fine-crystalline Zirconia Ceramics

The performances of fme-crystalline zirconia ceramics in workpiece ultrasonic vibration grinding （WUVG） and conventional grinding （CG） with diamond wheel were researched. The effects of WUVG and CG on material removal rate, grinding forces, surface roughness and microstructure of zirconia ceramic were investigated. Experimental results indicated that： （1） The material removal rate （MRR） in ultrasonic grinding process is two times as large as that of in conventional grinding. The material removal rate increases with increasing grinding depth in both ultrasonic grinding and conventional grinding. （2） The ultrasonic vibration grinding force is lower than that of conventional grinding force, and the increase of the worktable speed leads to a decrease of the grinding force, while the grinding force increases with larger grinding depth in both WUVG and CG. （3） The surface of ultrasonic vibration grinding has no spur and build-up edge and its surface roughness is smaller than that of CG significantly. Surface quality of WUVG is superior to that of conventional grinding, it is easy for ultrasonic vibration grinding that material removal mechanism is ductile grinding.

Comprehensive modeling approach of axial ultrasonic vibration grinding force

The theoretical model of axial ultrasonic vibration grinding force is built on the basis of a mathematical model of cutting deforming force deduced from the assumptions of thickness of the undeformed debris under Rayleigh distribution and a mathematical model of friction based on the theoretical analysis of relative sliding velocity of abrasive and workpiece. Then, the coefficients of the ultrasonic vibration grinding force model are calculated through analysis of nonlinear regression of the theoretical model by using MATLAB, and the law of influence of grinding depth, workpiece speed, frequency and amplitude of the mill on the grinding force is summarized after applying the model to analyze the ultrasonic grinding force. The result of the above-mentioned law shows that the grinding force decreases as frequency and amplitude increase, while increases as grinding depth and workpiece speed increase; the maximum relative error of prediction and experimental values of the normal grinding force is 11.47% and its average relative error is 5.41%; the maximum relative error of the tangential grinding force is 10.14% and its average relative error is 4.29%. The result of employing regression equation to predict ultrasonic grinding force approximates to the experimental data, therefore the accuracy and reliability of the model is verified.

Prediction of undeformed chip thickness distribution and surface roughness in ultrasonic vibration grinding of inner hole of bearings

Ultrasonic vibration grinding differs from traditional grinding in terms of its material removal mechanism.The randomness of grain-workpiece interaction in ultrasonic vibration grinding can produce variable chips and impact the surface roughness of workpiece.However,previous studies used iterative method to calculate the unformed chip thickness(UCT),which has low computational efficiency.In this study,a symbolic difference method is proposed to calculate the UCT.The UCT distributions are obtained to describe the stochastic interaction characteristics of ultrasonic grinding process.Meanwhile,the UCT distribution characteristics under different machining parameters are analyzed.Then,a surface roughness prediction model is established based on the UCT distribution.Finally,the correctness of the model is verified by experiments.This study provides a quick and accurate method for predicting surface roughness in longitudinal ultrasonic vibration grinding.

Separate critical condition for ultrasonic vibration assisted grinding

Separate characteristic of the tangential ultrasonic vibration assisted grinding (TUAG) machining is analyzed based on TUAG process, and a critical speed formula is given to correctly set the machining parameters to insure the separate characteristics of TUAG process. The critical speed is not only related to the ultrasonic vibration amplitude and frequency, but also to the grinding wheel velocity and the cutting point space, and the grinding force can be decreased during the TUAG process with separability. Grinding force experiments are conducted, and the experimental results are in good agreement with the theoretical results.

MECHANICAL-ELECTRIC COUPLING DYNAMICAL CHARACTERISTICS OF AN ULTRA-HIGH SPEED GRINDING MOTORIZED SPINDLE SYSTEM

On the basis of the traditional mechanical model of a grinding wheel rotor and the mechanical-electric coupling model with ideal sinusoidal supply, taking high-frequency converting current of inverter power switches into further consideration, a modified mechanical-electric coupling model is created. The created model consists of an inverter, a motorized spindle, a grinding wheel and grinding loads. Some typical non-stationary processes of the grinding system with two different supplies, including the starting, the speed rising and the break in grinding loads, are compared by making use of the created model. One supply is an ideal sinusoidal voltage source, the other is an inverter. The theoretical analysis of the high-order harmonic is also compared with the experimental result. The material strategy of suppressing high-order harmonic mechanical-electric coupling vibration by optimizing inverter operating parameters is proposed.

Vibration-assisted material damage mechanism:From indentation cracks to scratch cracks

Vibration-assisted grinding is one of the most promising technologies for manufacturing optical components due to its efficiency and quality advantages.However,the damage and crack propagation mechanisms of materials in vibration-assisted grinding are not well understood.In order to elucidate the mechanism of abrasive scratching during vibration-assisted grinding,a kinematic model of vibration scratching was developed.The influence of process parameters on the evolution of vibration scratches to indentation or straight scratches is revealed by displacement metrics and velocity metrics.Indentation,scratch and vibration scratch experiments were performed on quartz glass,and the results showed that the vibration scratch cracks are a combination of indentation cracks and scratch cracks.Vibration scratch cracks change from indentation cracks to scratch cracks as the indenter moves from the entrance to the exit of the workpiece or as the vibration frequency changes from high to low.A vertical vibration scratch stress field model is established for the first time,which reveals that the maximum principal stress and tensile stress distribution is the fundamental cause for inducing the transformation of the vibration scratch cracking system.This model provides a theoretical basis for understanding of the mechanism of material damage and crack propagation during vibration-assisted grinding.