Impact of geometrical parameters of ultrasonic-assisted grinding diamond tool on outlet stress and edge collapse of glass-ceramics

In the traditional grinding process, brittle materials such as glass-ceramics have great problems of outlet stress concentration and edge collapse. In order to solve the problem of edge collapse at the outlet of hard and brittle materials such as glass-ceramics in the process of axial hole machining, a simulation model of ultrasonic-assisted axial hole machining was established by finite element method, the influence of geometric parameters such as wall thickness, fillet and chamfer on the outlet stress is analyzed, and the optimized geometric parameters of the tool are obtained. The ultrasonic-assisted axial hole grinding experiments of glass-ceramics were carried out on the five-axis machining center with the optimized tool, and the edge collapse size was observed. The simulation results show that the optimized tool can significantly improve the stress concentration during axial machining. The experimental results show that the edge collapse size is significantly reduced and the outlet quality is relatively good, which verifies the accuracy of the simulation model.