Research on the matching relationship between ultrasonic-assisted grinding parameters and workpiece surface roughness

As a nontraditional type of processing technology, ultrasonic-assisted grinding (UAG) can effectively improve the surface integrity. A considerable research effort has been devoted to investigate the impact of various processing parameters on surface roughness. However, few studies have been conducted on the effects of matching relationship between different parameters. In this study, the numerical model of a dressed grinding wheel is constructed using a measured diamond pen. Based on the grinding kinematics, the micro surface topography of the workpiece is generated. The relationship between surface roughness and three main processing parameters is studied, and the concept of critical ultrasonic amplitude is proposed. It is found that the ultrasonic grinding can effectively weaken the deterioration of the roughness by increasing the depth of cut, and then, the relationship between the critical ultrasonic amplitude and the depth of cut is obtained. Furthermore, the coupling relation is explained from the angle of a single abrasive grain. Finally, the accuracy of the findings is verified by the experimental results, which may serve as an effective method or reference for the setting of ultrasonic grinding parameters.