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Study on force modeling considering size effect in ultrasonic-assisted micro-end grinding of silica glass and Al2O3 ceramic

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Ultrasonic vibration-assisted micro-end grinding (UAMEG) is a promising processing method for micro-parts made of hard and brittle materials. Grinding force is one of the most important parameters which can synthetically reflect the grinding process. So, it is a key issue to establish a model for the reliable prediction of grinding force in UAMEG. First, by studying removal mechanism and the micro-topography of grinding surface, the micro-end grinding zone is divided into the following three grinding regions: main grinding region, plowing grinding region, and sliding grinding region. Then, the single-grain force model is developed under different material removal modes, and the grinding force model of the whole grinding wheel is established considering size effect. To verify the correctness of the proposed model, contrast grinding tests of silica glass with and without ultrasonic assistance using micro-radial electroplated diamond wheel are conducted. The theoretical predicted values of grinding force match well with the experimental results. The grinding forces are significantly reduced, and ductile machining is easier to be achieved.

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Correspondence to Zhang Jianhua.

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Jianhua, Z., Hui, L., Minglu, Z. et al. Study on force modeling considering size effect in ultrasonic-assisted micro-end grinding of silica glass and Al2O3 ceramic. Int J Adv Manuf Technol 89, 1173–1192 (2017). https://doi.org/10.1007/s00170-016-9148-5

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  • Force model
  • Ultrasonic vibration
  • Micro-end grinding
  • Size effect
  • Ductile machining