Development of a novel ultrasonic unit for grinding of ceramic matrix composites

Ceramic matrix composites (CMCs) are promising materials for many high-technology engineering applications in harsh and severe environments due to their superior properties. However, in spite of all advantages, the employment of CMCs has been impeded by their high machining and finishing costs. Many of recently developed CMCs are very difficult to machine with the conventional machining technology, and improvement of the existing machining process is required and crucial. To overcome the existing technological constraints in the grinding of CMCs, a special designed block sonotrode was invented (and was registered for patent). The realization of ultrasonic-assisted machining on conventional machine tools can be carried out with much less effort by means of the new invented system. The invented block sonotrode is a specially designed perforated plate and demonstrates a multi-resonant frequency behavior. Experimental results illustrate the high performance of the presented method. A significant reduction in grinding forces and surface roughness and an increase in G-ratio have been achieved.