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Surface formation and damage mechanisms of nano-ZrO2 ceramics under axial ultrasonic-assisted grinding

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Abstract

In this study, the surface formation and damage mechanism of hard-brittle materials in axial ultrasonic-assisted grinding (AUAG) were revealed using the grinding force and grinding force ratio. Theoretical analysis presented that the grinding force and grinding force ratio in AUAG are relatively small. AUAG is a machining method with a large tangential force and a small normal force, which can promote the removal of hard-brittle materials and reduce the surface and subsurface damage (SSD). Scratching and grinding tests of nano-ZrO2 ceramics were conducted to validate the theoretical analysis. The results demonstrated that the periodic tangential force under the AUAG promotes the nucleation and propagation of shallower lateral micro-cracks, thereby allowing the easier removal of hard-brittle materials. Additionally, the proportion of brittle fracture was less, and the surface roughness and maximum SSD depth were significantly small. Therefore, AUAG is a suitable ultra-precision machining technique for hard-brittle materials.

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Abbreviations

A :

Ultrasonic amplitude

f :

Ultrasonic frequency

V w :

Feed rate of workpiece

V s :

Linear velocity of grinding

R :

Grinding wheel radius

a p :

Temperature or Celsius temperature scale

E :

Elastic modulus

h i :

The UCT

h m :

The maximum UCT

h :

The average UCT

K ID :

Dynamic fracture toughness

K IC :

Static fracture toughness

H V :

Vickers hardness

C h :

The depth of the lateral crack

C i :

The length of a lateral crack

C m :

The depth of the median crack

N d :

Dynamic distribution density of grains per area

N :

The number of active grains per area

F P :

The main cutting force acting on a unit cutting area

p :

The average contact pressure between the worn surface and the workpiece

F gt, F gn :

The tangential grinding force and the normal grinding force in CG

F tc, F nc :

The tangential force and the normal force generated by the cutting deformation

F ts, F ns :

The tangential force and the normal force generated by friction

F T, F N :

The tangential grinding force and the normal grinding force in AUAG

F tu, F nu :

The tangential force and the normal force of the periodic pulse force.

K F :

The grinding force ratio in AUAG

ω s :

Grinding wheel angular speed

ω :

Angular frequency of the workpiece

φ :

Initial phase of the ultrasonic vibration

6 :

Half-apex angle of particle

u :

Poisson’s ratio

σy :

Yield stress

ß :

Material parameter determined by elastic recovery

δ :

The top area of a particle

µ :

Friction coefficient

UAG :

Ultrasonic-assisted grinding

AUAG :

Axial ultrasonic-assisted grinding

SSD :

Subsurface damage

CG :

Conventional grinding

UCT :

Undeformed chip thickness

UAST :

Ultrasonic-assisted scratch test

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Acknowledgments

This research was sponsored by the National Natural Science Foundation of China (No. 51575163), Henan Polytechnic University Doctor Foundation project (No. B2010-76).

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Authors and Affiliations

  1. School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo, 454003, Henan, China

    Yanyan Yan, Yafei Zhang, Bo Zhao & Junli Liu

Authors
  1. Yanyan Yan
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  2. Yafei Zhang
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  3. Bo Zhao
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  4. Junli Liu
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Corresponding authors

Correspondence to Yanyan Yan or Yafei Zhang.

Additional information

Recommended by Editor Hyung Wook Park

Yanyan Yan is currently working at Henan Polytechnic University as an Associate Professor and a Master Tutor. She obtained a Doctor’s degree from School of Mechanical Engineering, Shanghai Jiao Tong University in 2009, and mainly is engaged in scientific research work, such as precision processing and ultraprecision processing of hard-brittle materials, advanced manufacturing technology and precision machining equipment, etc.

Yafei Zhang is a Master of the School of Mechanical and Power Engineering, Henan Polytechnic University. She obtained a Bachelor’s degree from this University in 2018. Her research interests include precision processing and ultra-precision processing of hard-brittle materials, ultrasonic assisted processing, etc.

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Yan, Y., Zhang, Y., Zhao, B. et al. Surface formation and damage mechanisms of nano-ZrO2 ceramics under axial ultrasonic-assisted grinding. J Mech Sci Technol 35, 1187–1197 (2021). https://doi.org/10.1007/s12206-021-0232-x

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  • DOI: https://doi.org/10.1007/s12206-021-0232-x

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