Research on the system matching model in ultrasonic vibration-assisted grinding

In this paper, the ultrasonic vibration-assisted grinding is studied, and a new method is provided to solve the problem of matching the machine tool system and the ultrasonic system. By establishing the matching model, this problem is theoretically solved optimally. Moreover, the abrasive grain motion equations, the removal rate model, and grinding force predictionmodel are presented. Then the grinding force and the processing quality in system matching are researched by numerical simulation. When ultrasonic system parameters exceed the critical value, the surface scallop height of workpiece becomes lower with single-grain track and intergranular track overlapping. The grinding force decreases as the spindle speed, vibration amplitude, and vibration frequency increase. And the grinding force increases as the grinding depth and feed rate increase. Thus, the surface morphology of the workpiece and the change trends of the grinding force can be predicted through the system matching model. As a result, the best ultrasonic equipment can be decided accordingly to cooperate with the machine tool for grinding.