Abstract
In recent years, the ultrasonic-assisted grinding (UAG) has found increasingly wider application in the processing of hard brittle materials due to the advantage of improving surface quality compared with common grinding. In the ultrasonic-assisted grinding process, the surface formation mechanism is different from that in the common grinding due to the high-frequency impulses on the workpiece. The nature of the method for common grinding is to solve the intersecting points of any two 2D cutting trajectories by simplifying the abrasive to a point or discretizing the abrasive for multiple points. However, this method does not apply to the ultrasonic-assisted grinding since the cutting trajectory of the grit is a three-dimensional space curve, which may make it difficult to find the intersecting points of any two cutting trajectories. To overcome this problem, a method for predicting the ground surface roughness of the ultrasonic-assisted grinding is developed in this paper. First, the abrasive grain trajectory surface equation as a function of time is established considering the ultrasonic vibration of the workpiece and the shape of the grain. Subsequently, a new simulation model for the surface topography of the grinding process is proposed by dividing up the workpiece into a grid and calculating the minimum value of all grains left at each grid point. Finally, experimental verification is performed, and the influence of the ultrasonic vibration amplitude on surface roughness is discussed. The simulation shows that the proposed method yields the results that are consistent with the experiment, thereby proving the effectiveness of the method.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Tawakoli T, Azarhoushang B (2008) Influence of ultrasonic vibrations on dry grinding of soft steel. Int J Mach Tools Manuf 48(14):1585–1591. doi:10.1016/j.ijmachtools.2008.05.010
Nik MG, Movahhedy MR, Akbari J (2012) Ultrasonic-assisted grinding of Ti6Al4V alloy. Procedia CIRP 1:353–358. doi:10.1016/j.procir.2012.04.063
Liang Z, Wang X, Wu Y, Xie L, Liu Z, Zhao W (2012) An investigation on wear mechanism of resin-bonded diamond wheel in Elliptical Ultrasonic Assisted Grinding (EUAG) of monocrystal sapphire. J Mater Process Technol 212(4):868–876. doi:10.1016/j.jmatprotec.2011.11.009
Bhaduri D, Soo SL, Aspinwall DK, Novovic D, Harden P, Bohr S, Martin D (2012) A study on ultrasonic assisted creep feed grinding of nickel based superalloys. Procedia CIRP 1:359–364. doi:10.1016/j.procir.2012.04.064
Farhadi A, Abdullah A, Zarkoob J, Pak A (2010) Analytical and Numerical Simulation of Ultrasonic Assisted Grinding. In: ASME 2010 10th Biennial Conference on Engineering Systems Design and Analysis. American Society of Mechanical Engineers, pp 763-768
Yan YY, Zhao B, Liu JL (2008) Ultraprecision surface finishing of nano-ZrO2 ceramics using two-dimensional ultrasonic assisted grinding. Int J Adv Manuf Technol 43(5–6):462–467. doi:10.1007/s00170-008-1732-x
Gao GF, Zhao B, Xiang DH, Kong QH (2009) Research on the surface characteristics in ultrasonic grinding nano-zirconia ceramics. J Mater Process Technol 209(1):32–37. doi:10.1016/j.jmatprotec.2008.01.061
Chen HF, Tang JY, Lang XJ, Huang YH, He YL (2014) Influences of dressing lead on surface roughness of ultrasonic-assisted grinding. Int J Adv Manuf Technol 71(9–12):2011–2015. doi:10.1007/s00170-014-5636-7
Malkin S, Guo CS (eds) (2008) Grinding technology: theory and application of machining with abrasive. Wiley, New York
Zhou X, Xi F (2002) Modeling and predicting surface roughness of the grinding process. Int J Mach Tools Manuf 42:969–977
Nguyen TA, Butler DL (2005) Simulation of surface grinding process, part 2: interaction of the abrasive grain with the workpiece. Int J Mach Tools Manuf 45(11):1329–1336. doi:10.1016/j.ijmachtools.2005.01.006
Cao Y, Guan J, Li B, Chen X, Yang J, Gan C (2012) Modeling and simulation of grinding surface topography considering wheel vibration. Int J Adv Manuf Technol 66(5–8):937–945. doi:10.1007/s00170-012-4378-7
Chen X, Rowe WB (1996) Analysis and simulation of the grinding process. Part I: generation of the grinding wheel. Int J Mach Tools Manuf 36(8):871–882
Chen X, Rowe WB (1996) Analysis and simulation of the grinding process. Part 2: mechanics of grinding. Int J Mach Tools Manuf 36(8):883–896
Liu Y, Warkentin A, Bauer R, Gong Y (2013) Investigation of different grain shapes and dressing to predict surface roughness in grinding using kinematic simulations. Precis Eng 37(3):758–764
Hou ZB, Komanduri R (2003) On the mechanics of the grinding process—part I. Stochastic nature of the grinding process. Int J Mach Tools Manuf 43(15):1579–1593. doi:10.1016/s0890-6955(03)00186-x
Chen HF, Tang JY, Zhou W (2013) An experimental study of the effects of ultrasonic vibration on grinding surface roughness of C45 carbon steel. Int J Adv Manuf Technol 68(9–12):2095–2098
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Chen, H., Tang, J. A model for prediction of surface roughness in ultrasonic-assisted grinding. Int J Adv Manuf Technol 77, 643–651 (2015). https://doi.org/10.1007/s00170-014-6482-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-6482-3