Ultrasonic vibration grinding of difficult-to-cut materials: force models and processability

Abstract

Grinding force is an essential metric for determining whether a material is grindable. It can directly affect surface integrity, machining efficiency, and tool life. Therefore, the mechanical behavior of grinding has long been a topic of research. A large number of studies have demonstrated that ultrasonic vibration-assisted grinding (UVAG) reduces grinding force and improves surface quality after grinding. However, these studies have many gaps, and the mechanism underlying UVAG force has not been explored. First, the study investigates the influence of grinding and ultrasonic vibration parameters on grinding force with an empirical model based on statistical theory. Second, the material removal mechanism of UVAG is investigated using a finite element model, and the mechanical properties and grinding force evolution mechanism of various materials (difficult-to-cut alloys, brittle materials, and composite materials) for UVAG are reviewed. Simultaneously, a mathematical analysis model of ultrasonic-assisted grinding force based on kinematics and separation characteristics is presented. The error comparison and source analysis of the grinding force model are performed. Finally, based on the current difficulties and research gaps in the UVAG force model, various future research directions are proposed.

Graphical abstract

Keywords

ultrasonic vibration grinding / grinding force / empirical model / finite element model / mathematical analysis model

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