Abstract
Ultrasonic assisted dry grinding (UADG) is a novel green manufacturing technology for decreasing the negative environment impact of cutting fluids and improving the surface characteristics. In this study, the influences of the ultrasonic amplitude, grinding depth and grinding velocity on the surface roughness in ultrasonic assisted dry grinding of 12Cr2Ni4A with a large CBN grinding wheel were investigated. Due to the Poisson effect, the ultrasonic assisted dry grinding using a large diameter grinding wheel is the combination of axial ultrasonic assisted grinding and radial ultrasonic assisted grinding. The results indicated that the main axial ultrasonic component tended to smooth the surface topography by increasing the interaction overlap of the adjacent cutting traces, but it would result in more side flow/ploughing on the surface at a larger ultrasonic amplitude; the radial ultrasonic component exerted a function on the increase of the surface roughness through deepening the individual grinding trajectories. Thus, the surface roughness decreased first and then increased with the increase of grinding depth due to the combined contribution of axial and radial vibrations. However, the improving effect of ultrasonic vibration on the surface roughness gradually weakened with the increase of grinding velocity. Under proper operating parameters, surface roughness obtained in ultrasonic assisted dry grinding can be reduced up to 30% compared with that of common dry grinding.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Sharma, A. K., Tiwari, A. K., and Dixit, A. R., “Effects of Minimum Quantity Lubrication (MQL) in Machining Processes Using Conventional and Nanofluid Based Cutting Fluids: A Comprehensive Review,” Journal of Cleaner Production, vol. 127, pp. 1–18, 2016.
Kumaran, S. T., Ko, T. J., Li, C., Yu, Z., and Uthayakumar, M., “Rotary Ultrasonic Machining of Woven CFRP Composite in a Cryogenic Environment,” Journal of Alloys and Compounds, vol. 698, pp. 984–993, 2017.
Shan, C., Zhang, X., Dang, J., and Yang, Y., “Rotary Ultrasonic Drilling of Needle-Punched Carbon/Carbon Composites: Comparisons with Conventional Twist Drilling and High-Speed Drilling,” The International Journal of Advanced Manufacturing Technology, 2017. (DOI: 10.1007/s00170-017-1228-7)
Qi, H., Wen, D., Lu, C., and Li, G., “Numerical and Experimental Study on Ultrasonic Vibration-Assisted Micro-Channelling of Glasses Using an Abrasive Slurry Jet,” International Journal of Mechanical Sciences, vol. 110, pp. 94–107, 2016.
Qi, H., Wen, D., Yuan, Q., Zhang, L., and Chen, Z., “Numerical Investigation on Particle Impact Erosion in Ultrasonic-Assisted Abrasive Slurry Jet Micro-Machining of Glasses,” Powder Technology, vol. 314, pp. 627–634, 2017.
Watanabe, T., Sakuyama, H., and Yanagisawa, A., “Ultrasonic Welding between Mild Steel Sheet and Al-Mg Alloy Sheet,” Journal of Materials Processing Technology, Vol. 209, Nos. 15–16, pp. 5475–5480, 2009.
Tawakoli, T. and Azarhoushang, B., “Influence of Ultrasonic Vibrations on Dry Grinding of Soft Steel,” International Journal of Machine Tools and Manufacture, vol. 48, no. 14, pp. 1585–1591, 2008.
Li, C., Zhang, F., Meng, B., Liu, L., and Rao, X., “Material Removal Mechanism and Grinding Force Modelling of Ultrasonic Vibration Assisted Grinding for SiC Ceramics,” Ceramics International, vol. 43, no. 3, pp. 2981–2993, 2017.
Gong, H., Fang, F., and Hu, X., “Kinematic View of Tool Life in Rotary Ultrasonic Side Milling of Hard and Brittle Materials,” International Journal of Machine Tools and Manufacture, vol. 50, no. 3, pp. 303–307, 2010.
Chen, H., Tang, J., Lang, X., Huang, Y., and He, Y., “Influences of Dressing Lead on Surface Roughness of Ultrasonic-Assisted Grinding,” The International Journal of Advanced Manufacturing Technology, Vol. 71, Nos. 9–12, pp. 2011–2015, 2014.
Abdullah, A., Sotoodezadeh, M., Abedini, R., and Fartashvand, V., “Experimental Study on Ultrasonic Use in Dry Creep-Feed Up-Grinding of Aluminum 7075 and Steel X210Cr12,” International Journal of Precision Engineering and Manufacturing, vol. 14, no. 2, pp. 191–198, 2013.
Molaie, M., Akbari, J., and Movahhedy, M., “Ultrasonic Assisted Grinding Process with Minimum Quantity Lubrication Using Oil-Based Nanofluids,” Journal of Cleaner Production, vol. 129, pp. 212–222, 2016.
Paknejad, M., Abdullah, A., and Azarhoushang, B., “Effects of High Power Ultrasonic Vibration on Temperature Distribution of Workpiece in Dry Creep Feed up Grinding,” Ultrasonics Sonochemistry, vol. 39, pp. 392–402, 2017.
Chen, H., Tang, J., and Zhou, W., “An Experimental Study of the Effects of Ultrasonic Vibration on Grinding Surface Roughness of C45 Carbon Steel,” The International Journal of Advanced Manufacturing Technology, Vol. 68, Nos. 9–12, pp. 2095–2098, 2013.
Chen, H. and Tang, J., “Influence of Ultrasonic Assisted Grinding on Abbott-Firestone Curve,” The International Journal of Advanced Manufacturing Technology, Vol. 86, Nos. 9–12, pp. 2753–2757, 2016.
Wang, Y., Lin, B., Wang, S., and Cao, X., “Study on the System Matching of Ultrasonic Vibration Assisted Grinding for Hard and Brittle Materials Processing,” International Journal of Machine Tools and Manufacture, vol. 77, pp. 66–73, 2014.
Wei, S., Zhao, H., and Jing, J., “Investigation on Three-Dimensional Surface Roughness Evaluation of Engineering Ceramic for Rotary Ultrasonic Grinding Machining,” Applied Surface Science, vol. 357, pp. 139–146, 2015.
Cao, J., Wu, Y., Lu, D., Fujimoto, M., and Nomura, M., “Material Removal Behavior in Ultrasonic-Assisted Scratching of SiC Ceramics with a Single Diamond Tool,” International Journal of Machine Tools and Manufacture, vol. 79, pp. 49–61, 2014.
Li, S., Wu, Y., and Nomura, M., “Effect of Grinding Wheel Ultrasonic Vibration on Chip Formation in Surface Grinding of Inconel 718,” The International Journal of Advanced Manufacturing Technology, Vol. 86, Nos. 1–4, pp. 1113–1125, 2016.
Chou, C.-L., “Wave Effects of Ultrasonic Vibration on Machining,” Pennsylvania State University, 1994.
Yanyan, Y., Bo, Z., and Junli, L., “Ultraprecision Surface Finishing of Nano-ZrO2 Ceramics Using Two-Dimensional Ultrasonic Assisted Grinding,” The International Journal of Advanced Manufacturing Technology, Vol. 43, Nos. 5–6, pp. 462–467, 2009.
Liang, Z., Wu, Y., Wang, X., and Zhao, W., “A New Two-Dimensional Ultrasonic Assisted Grinding (2D-UAG) Method and Its Fundamental Performance in Monocrystal Silicon Machining,” International Journal of Machine Tools and Manufacture, vol. 50, no. 8, pp. 728–736, 2010.
Chen, J. B., Fang, Q. H., Wang, C. C., Du, J. K., and Liu, F., “Theoretical Study on Brittle-Ductile Transition Behavior in Elliptical Ultrasonic Assisted Grinding of Hard Brittle Materials,” Precision Engineering, vol. 46, pp. 104–117, 2016.
Tang, J., Du, J., and Chen, Y., “Modeling and Experimental Study of Grinding Forces in Surface Grinding,” Journal of Materials Processing Technology, vol. 209, no. 6, pp. 2847–2854, 2009.
Guo, B. and Zhao, Q., “Ultrasonic Vibration Assisted Grinding of Hard and Brittle Linear Micro-Structured Surfaces,” Precision Engineering, vol. 48, pp. 98–106, 2017.
Wang, Y., Lin, B., Cao, X., and Wang, S., “An Experimental Investigation of System Matching in Ultrasonic Vibration Assisted Grinding for Titanium,” Journal of Materials Processing Technology, vol. 214, no. 9, pp. 1871–1878, 2014.
Liang, Z., Wang, X., Wu, Y., Xie, L., Liu, Z., and Zhao, W., “An Investigation on Wear Mechanism of Resin-Bonded Diamond Wheel in Elliptical Ultrasonic Assisted Grinding (EUAG) of Monocrystal Sapphire,” Journal of Materials Processing Technology, vol. 212, no. 4, pp. 868–876, 2012.
Wang, Q., Zhao, W., Liang, Z., Wang, X., Zhou, T., et al., “Investigation of Diamond Wheel Topography in Elliptical Ultrasonic Assisted Grinding (EUAG) of Monocrystal Sapphire Using Fractal Analysis Method,” Ultrasonics, vol. 84, pp. 87–95, 2018.
Shen, J., Wang, J., Jiang, B., and Xu, X., “Study on Wear of Diamond Wheel in Ultrasonic Vibration-Assisted Grinding Ceramic,” Wear, Vols. 332–333, pp. 788–793, 2015.
Author information
Authors and Affiliations
Corresponding authors
Rights and permissions
About this article
Cite this article
Chen, HF., Tang, JY., Shao, W. et al. An Investigation of Surface Roughness in Ultrasonic Assisted Dry Grinding of 12Cr2Ni4A with Large Diameter Grinding Wheel. Int. J. Precis. Eng. Manuf. 19, 929–936 (2018). https://doi.org/10.1007/s12541-018-0110-3
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12541-018-0110-3