Modelling and experimental study on brittle-to-ductile transition during ultrasonic elliptical vibration-assisted cutting of zirconia ceramics

Abstract

Zirconia ceramics are often used in electronics, aerospace, biomedicine, and other fields because of their excellent mechanical and optical properties; however, as they are hard and brittle materials, they are highly susceptible to cracking and chipping during processing. Ultrasonic elliptical vibratory-assisted cutting (UEVC) is a promising ceramic processing technology that addresses existing problems in materials processing. In this study, the critical depth of cut (

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) of zirconia ceramics was predicted using two models, focusing on the influence of the circular edge of the tool and tool front angle in the actual machining process. Subsequently, a model was established based on the specific cutting energy to predict the

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of zirconia ceramics in UEVC machining. A simulation software was used to simulate the variable depth of zirconia ceramics using the constitutive improved Johnson-Holmquist ceramic (JH-2) model. Finally, the relationship between the cutting speed and

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of zirconia ceramics under conventional cutting (CC) and UEVC machining was investigated using scribing experiments. The results showed that the

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of zirconia ceramics decreased nonlinearly with increasing cutting speed. The

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of zirconia under CC is 0.8 μm, whereas the

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values of zirconia under UEVC machining are 1.79, 1.75, 1.45, and 1.3 μm with a maximum increment of 124%, which corroborates the results predicted by the model, verifying the effectiveness of the model and simulation.

Keywords

Ultrasonic elliptical vibration-assisted cutting (UEVC) / Zirconia ceramic / Brittle-to-ductile transition (BDT) / Specific cutting energy / Finite element simulation / Scribing experiment

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Funding

Key R&D projects of Jilin Provincial Department of Science and Technology(20240302037GX)

Natural Science Foundation of Jilin Province(YDZJ202301ZYTS258)

Jilin Provincial International Cooperation Key Laboratory for High-Performance Manufacturing and Testing(20220502003GH)

RIGHTS & PERMISSIONS

Shanghai University and Periodicals Agency of Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature