Effects of Cutting Edge Truncation on Ultrasonically Assisted Grinding

Abstract

Dies for injection molded parts require high-quality surface finishes in terms of both appearance and integrity. Manual finishing by skilled workers is required to produce such surfaces, but this takes several days. To minimize the amount of polishing required, a new finishing technique that employs ultrasonically assisted diamond grinding was proposed in a previous report. Cutting edge truncation prior to grinding is required to produce a mirror surface. In this study, the effect of cutting edge truncation was investigated and the relationships between the ground surface roughness and the cutting torque and the thrust force were considered to optimize the grinding conditions for mirror surface finishing.

Geometrical transcription of diamond electroplated tool in ultrasonic vibration assisted grinding of steel

“…In another report [2] the necessity of truncating the sharply protruded grain tips as a condition to obtain better surface finish was clarified, but the optimum truncation condition or method is unclear. Despite using the same 2 mm diameter tool, the reports [1][2][3][4][5] showed different machining condition (i.e., the spindle speed); from 4000 rpm to 2000 rpm or lower and depth of cut; from no clear effect to the smaller the better, in relation to works surface roughness. The changes indicate certain instability of the UVAG system while the most uncertain element of the grinding system is the tool-work interaction between the DET working surface and ground surface during grinding, and the analysis on the geometrical properties of the DET working surface topography is necessary to clarify the matter.…”