Study on the material removal mechanism and the exit breakage of ultrasonic vibration-assisted grinding for microcrystalline glass

• Published in: Discover Applied Sciences Vol. 6; no. 3; p. 133
• Main Authors: Zhang, Wenchao, Cui, Enming, Zhang, Baoquan, Wang, Mingwei, Zhao, Xiujun
• Format: Journal Article
• Language: English
• Published: Cham Springer International Publishing 14.03.2024; Springer Nature B.V
• Subjects: Applied and Technical Physics; Breakage; Brittle materials; Chemistry/Food Science; Constitutive models; Diamond machining; Diamonds; Earth Sciences; Edge stresses; Engineering; Environment; Feed rate; Finite element method; Grinding; Grit; Materials Science; Mathematical models; Microcracks; Morphology; Process parameters; Simulation; Simulation models; Software; Surface properties; Surface roughness; Trajectory analysis; Ultrasonic vibration; Vibration; Vibration analysis; White light; Workpieces; Surface quality; Microcrystalline glass; Exit breakage; Process parameters; Grinding force
• ISSN: 2523-3963; 3004-9261; 2523-3971
• DOI: 10.1007/s42452-024-05790-9

With the aim of solving problems such as exit breakage and surface microcracks during microcrystalline glass machining, an ellipsoidal erosion model is established by analyzing the motion trajectory and characteristics of single diamond grit in ultrasonic vibration-assisted grinding (UVAG), and the material removal volume of single diamond grit particles is obtained. A simulation model of UVAG of microcrystalline glass is established by the finite element method. The effect of process parameters such as rotational speed, grinding depth, feed rate on grinding force and workpiece edge stress has been investigated. The experiment of UVAG for microcrystalline glass is performed on a five-axis CNC machine with the same process parameters, and the surface morphology, surface roughness, and exit breakage sizes of microcrystalline glass are observed. The results show that with the increase in grinding depth, the average grinding force between the tool and the workpiece increases, and the proportion of material removal in a brittle fracture increases. As the rotational speed increases, the grinding force between the tool and the workpiece gradually decreases and results in an improvement in the surface quality of the workpiece. As the feed rate increases, the surface roughness increases by 16.76%, the width of the edge breakage increases by 109.19%, and the thickness of the edge breakage increases by 104.49%. Article highlights Considering ultrasonic vibration, the trajectory and characteristics of a single diamond grit is analyzed and a model of ellipsoidal erosion is established. The material removal volume in the case of single diamond grit grinding is obtained. The removal mechanism of hard and brittle materials as well as the surface quality after machining are investigated and analyzed by comparing the grinding force and exit stress of the workpiece under various process parameters. The finite element simulation model of UVAG of microcrystalline glass is established based on the JH2 constitutive model, and the effect of process parameters on grinding force and exit stress is obtained. The three-dimensional force sensor is used to obtain grinding forces during machining. The surface morphology of workpiece is observed by SEM and measured by white-light interferometer. The reliability of the simulation model is verified by comparing the experimental results with the simulation results.