Experimental study on ultrasonic vibration-assisted grinding of hardened steel using white corundum wheel

Huang, Qiang; Zhao, Biao; Cao, Yang; Ding, Wenfeng; Fu, Yucan; Pu, Changlan; Tang, Menglan; Deng, Mingming; Liu, Guoliang

doi:10.1007/s00170-022-09473-w

Cited by 16 publications

(9 citation statements)

References 33 publications

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“…Tang et al [21] analyzed the instantaneous contact interface state under ultrasonic vibration, and elaborated the friction reduction mechanism of UVAG. Similarly, the UVAG process improves the heat transfer ability of coolant and the self-sharpening ability of abrasives, resulting in a lower grinding force and temperature, as described in other literatures [22][23][24][25]. Moreover, UVAG has proved to be an efficient technique for machining brittle materials [26][27][28][29].…”

Section: Introductionmentioning

confidence: 74%

“…In recent years, ultrasonic vibration-assisted grinding (UVAG) technology has been widely concerned, aiming at obtaining high surface integrity, especially for difficult-to-cut materials in aerospace industries [16]. Those researches show that the usage of ultrasonic composite technology contributes to the reduction of the grinding forces and temperature, the significantly improvement of grinding quality, and an enhancement in material removal rate during machining difficult-to-cut materials [17][18][19][20][21][22][23][24][25]. Ding et al [17] developed a radial ultrasonic vibration-assisted machining device and applied it to machining the particle-reinforcing titanium matrix composites.…”

Section: Introductionmentioning

confidence: 99%

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Grindability of γ-TiAl intermetallic compounds during ultrasonic vibration-assisted high efficiency deep grinding process

Wang

Tang

Zhao

et al. 2023

Int J Adv Manuf Technol

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Gamma titanium-aluminum intermetallic compounds (γ-TiAl) have an important application significance in the field of aero-engines owing to their excellent mechanical properties (e.g., high-temperature resistance, high toughness, etc). Grinding as an important method was used to realize the high efficiency and precise machining for difficult-to-cut materials. However, the machining defects (e.g., adhesion, cracks, and even burns, etc) were confronted on machined surface of γ-TiAl materials under high grinding force and temperature loads. In this case, the new machining methods combined with the ultrasonic vibration and high-efficiency deep grinding technology was proposed to improve the machining quality and efficiency. Comparative trials of ultrasonic vibration-assisted high efficiency deep grinding (UVHEDG) and high efficiency deep grinding (HEDG) were carried out to study the grinding performance, in terms of the grinding force, grinding temperature, specific grinding energy, and machining surface quality. Results show that UVHEDG possess the lower grinding force and temperature by 38.69% and 39.05% compared with HEDG, respectively. In addition, the employment of ultrasonic vibrations contributes to maintain the abrasive sharpness, and thus the specific grinding energy is reduced by 23.95%. Ground surface roughness can be reduced by 19.53%, and the grinding surface quality is effectively improved due to the lubrication effect and track overlap effect under ultrasonic vibration.

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Section: Introductionmentioning

confidence: 74%

Section: Introductionmentioning

confidence: 99%

Grindability of γ-TiAl intermetallic compounds during ultrasonic vibration-assisted high efficiency deep grinding process

Wang

Tang

Zhao

et al. 2023

Int J Adv Manuf Technol

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“…The ultrasonic relative motion trajectory of a single AcBN grain with the workpiece can be regarded as a periodic reciprocating vibration superimposed along the tangential direction in CG. According to Huang et al [40], the equation of motion of a single AcBN grain twice adjacent in CG can be expressed as follows:…”

Section: Motion Trajectory Of Single Acbn Grainmentioning

confidence: 99%

Wear mechanism of aggregated cBN grains during single-grain ultrasonic vibration-assisted grinding of γ-TiAl alloys

Song,

Zhao,

Ding

et al. 2024

Preprint

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In this study, the wear mechanism of single aggregated cubic boron nitride (AcBN) grain during ultrasonic vibration-assisted grinding is investigated. The single AcBN grinding experiment are conducted under conventional grinding and ultrasonic vibration-assisted grinding on gamma titanium-aluminum intermetallic compounds, and the grain wear mechanism is comprehensively revealed by observing the radial wear height, normal force, average volume pile-up ratio, and morphology evolution of the grains with different maximum undeformed chip thicknesses, grinding speeds, and ultrasonic amplitudes. The experimental results show that the introduction of ultrasonic vibration produces periodic vibration of the workpiece in the tangential direction, which can produce intermittent dissociative behavior and effectively reduce normal force and average volume pile-up ratio of single AcBN grains when grinding, but also makes the instantaneous maximum undeformed chip thickness increase and introduces the periodic impact force, which accelerates the radial wear height of the AcBN grains. In addition, the ultrasonic vibration can effectively reduce the material adhesion in the AcBN grains surface and cause it to continuously undergo micro-fracture has better self-sharpening ability. In addition, excessive ultrasonic amplitude will lead to AcBN grains to occur macro-fracture and the expansion of bond cracks lead to abrasive grains pulling out, losing partial grinding ability.

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“…Rather than a constant, the varied instantaneous cutting depth affects overall process stability and machining accuracy [3,4,7,8 ,9]. Ultrasonic vibration-assisted grinding (UVAG) technology [12][13][14][15][16] possesses many advantages, such as high processing efficiency and quality surface and low process costs, for hard and brittle materials or difficult-to-machine materials. Compared with the other traditional machining technologies, the principle of UVAG technology conducts periodic material removal behaviors of "intermittent impact" and "discontinuous grinding" by exerting one-dimensional or two-dimensional ultrasonic vibrations on abrasive wheel or workpiece in corresponding to axial and feed directions.…”

Section: Introductionmentioning

confidence: 99%

“…The "intermittent impact" promotes the short interactions between microcutting-edges of abrasive grits and workpiece and produces the extremely high local stress in the workpiece leading to the generation and propagation micro-crack and further local material fragmentation and removal. According to the correlations between process parameters and ground surface quality in UVAG, Wang, Huang and Zahedi et al [12][13][14] studied the matching strategy on the UVAG process condition selections and proposed an optimization solution to improve machining quality of titanium alloy materials within a proper range of grinding speed. Aiming at the decrease of grinding force and the improvement of grinding wheel shape accuracy, Qiao et al [15] studied the influence of UVAG on the truing/dressing of metal-resin-bonded diamond grinding wheel, and revealed that the increase of the ultrasonic amplitude could lead the decrease of truing/dressing force, the increase of material removal rate and a significant improvement of machining accuracy.…”

Section: Introductionmentioning

confidence: 99%

Comprehensive Influence of Ultrasonic Vibration-Assisted Technology on Material Removal Mechanism under the Excitation of Regenerative Vibration in Precision Grinding Process

chen

Chen²,

Huang³

et al. 2023

Preprint

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Self-excited regenerative vibration, a well-known endogenous excitation mechanism, has a critical influence on material removal behavior and ground surface generation in a precision grinding process. During ultrasonic vibration-assisted grinding (UVAG), one-dimensional or two-dimensional ultrasonic vibration exerted to abrasive wheel or workpiece in axial and feed directions will influence material removing process significantly. Focusing on the study on the coupling relationship between ultrasonic vibration (as an external forced vibration) and regenerative vibration (as an internal vibration) excited by adjacent active abrasive grits, the improved theoretical models of cutting depth of abrasive grits and phase difference of grinding trajectory paths between adjacent active abrasive grits were presented in the paper with the consideration of the relationships between the ultrasonic vibration frequency, active abrasive grit number in contact zone and abrasive wheel speed. An optimization control strategy was further put forward by means of adjusting ultrasonic vibration frequency and the corresponding ratio to obtain proper phase difference of grinding trajectory paths of abrasive grits, which resulted to the improvement of cutting depth distribution and high surface finish of workpiece. The experiments of UVAG were conducted to verify the reliability of the influential mechanism and the validity of theorical model of cutting depth. Compared with the morphological characteristics of scratch section on the workpiece surface in axial cross-section before and after adjustment of ultrasonic vibration frequency, the results indicated that the numbers of active abrasive grits in contact zone increased with the increase of ultrasonic vibration frequency. When the vibration phase difference between grinding trajectory paths of adjacent abrasive grits was optimized to be an odd multiple of π/2 by stipulating proper ultrasonic vibration frequency, the vibratory amplitude of active abrasive grits decreases. As a result, the cutting depth of abrasive grits and the distribution of workpiece surface waviness were comparatively uniform, and the average surface roughness measured in five groups of experiments decrease by up to 27% in comparing with those without UVAG. In contrast, when the vibration phase difference was an even multiple of π/2, the amplitude of workpiece surface waviness reached to its maximum due to the double excitation effects of regenerative vibration and ultrasonic vibration, the surface roughness worsened by 23%. The finding provides a clear guidance to the preparation of structured abrasive tools and matching strategy of process parameters in UVAG.

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Experimental study on ultrasonic vibration-assisted grinding of hardened steel using white corundum wheel

Cited by 16 publications

References 33 publications

Grindability of γ-TiAl intermetallic compounds during ultrasonic vibration-assisted high efficiency deep grinding process

Grindability of γ-TiAl intermetallic compounds during ultrasonic vibration-assisted high efficiency deep grinding process

Wear mechanism of aggregated cBN grains during single-grain ultrasonic vibration-assisted grinding of γ-TiAl alloys

Comprehensive Influence of Ultrasonic Vibration-Assisted Technology on Material Removal Mechanism under the Excitation of Regenerative Vibration in Precision Grinding Process

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