Abstract
In the precision fabrication industries, ultrasonic vibration-assisted grinding is widely utilized for the finishing of “difficult-to-cut” materials due to its intermittent cutting mechanism and brittle-to-ductile mode machining. In this study, a two-dimensional finite element model (FEM) of single grit ultrasonic vibration-assisted dry grinding (UVADG) and conventional dry grinding (CDG) of AISI D2 steel has been developed, which taken into account the influence of longitudinal ultrasonic vibration on the workpiece with variable downfeed. The effects of ultrasonic vibration and downfeed on the chip formation mechanism, temperature field, grinding force, and equivalent stress and strain were evaluated by analytical and simulation methods. The results show that the formation of the grinding chips under UVADG is much shorter and straighter than CDG mode at all respective downfeed. The validation experiment compared the simulated and experimental grinding force in both grinding modes to verify the reliability of the FEM results. The validation results demonstrate that the FEM model can accurately describe the single grit UVADG and CDG grinding. At each downfeed, the CDG mode has generated a larger equivalent plastic strain than the UVADG mode, resulting in a higher thermomechanical load on the workpiece. According to the findings, UVADG mode has the least plastic damage on the ground surface, which may improve the surface integrity of the ground component.
Issue Section:
Research Papers
References
1.
Tawakoli
, T.
, Hadad
, M. J.
, Sadeghi
, M. H.
, Daneshi
, A.
, Stöckert
, S.
, and Rasifard
, A.
, 2009
, “An Experimental Investigation of the Effects of Workpiece and Grinding Parameters on Minimum Quantity Lubrication-MQL Grinding
,” Int. J. Mach. Tools Manuf.
, 49
(12–13
), pp. 924
–932
. 2.
Marinescu
, I. D.
, Hitchiner
, M.
, Uhlmann
, E.
, Rowe
, W. B.
, and Inasaki
, I.
, 2016
, Handbook of Machining With Grinding Wheels
, CRC Press
, Boca Raton, FL
, pp. 1
–598
.3.
Sinha
, M. K.
, Setti
, D.
, Ghosh
, S.
, and Venkateswara Rao
, P.
, 2016
, “An Investigation on Surface Burn During Grinding of Inconel 718
,” J. Manuf. Process.
, 21
(5
), pp. 124
–133
. 4.
Chaudhari
, A.
, Yusufzai
, M. Z. K.
, and Vashista
, M.
, 2021
, “Grindability Study of Hard to Cut AISI D2 Steel Upon Ultrasonic Vibration-Assisted Dry Grinding
,” Proc. Inst. Mech. Eng., Part E
, 235
, p. 095440892110516
. 5.
Wood
, R. W.
, and Loomis
, A. L.
, 1927
, “XXXVIII. The Physical and Biological Effects of High-Frequency Sound-Waves of Great Intensity
,” Lond. Edinb. Dublin Philos. Mag. J. Sci.
, 4
(22
), pp. 417
–436
. 6.
Wang
, Y.
, Kang
, R.
, Dong
, Z.
, Wang
, X.
, Huo
, D.
, and Zhang
, X.
, 2021
, “A Novel Method of Blade-Inclined Ultrasonic Cutting Nomex Honeycomb Core With Straight Blade
,” ASME J. Manuf. Sci. Eng.
, 143
(4
), p. 041012
. 7.
Yin
, S.
, Dong
, Z.
, Bao
, Y.
, Kang
, R.
, Du
, W.
, Pan
, Y.
, and Jin
, Z.
, 2021
, “Development and Optimization of Ultrasonic Elliptical Vibration Cutting Device Based on Single Excitation
,” ASME J. Manuf. Sci. Eng.
, 143
(8
), p. 081005
. 8.
Lv
, D.
, Liu
, D.
, Chen
, G.
, Song
, L.
, Yan
, C.
, Wu
, X.
, and Zhu
, Y.
, 2020
, “Formation Mechanisms of Exit-Chippings in Rotary Ultrasonic Drilling and Conventional Drilling of Glass BK7
,” ASME J. Manuf. Sci. Eng.
, 142
(1
), p. 011004
. 9.
Ning
, F.
, Jiang
, D.
, Liu
, Z.
, Wang
, H.
, and Cong
, W.
, 2021
, “Ultrasonic Frequency Effects on the Melt Pool Formation, Porosity, and Thermal-Dependent Property of Inconel 718 Fabricated by Ultrasonic Vibration-Assisted Directed Energy Deposition
,” ASME J. Manuf. Sci. Eng.
, 143
(5
), p. 051009
. 10.
Song
, H.
, Li
, M.
, Wang
, M.
, Wu
, B.
, Liu
, Z.
, Ding
, H.
, and Liu
, W.
, 2021
, “Preliminary Experimental Study of Warm Ultrasonic Impact-Assisted Laser Metal Deposition
,” ASME J. Manuf. Sci. Eng.
, 143
(7
), p. 074501
. 11.
Ituarte
, I. F.
, Salmi
, M.
, Papula
, S.
, Huuki
, J.
, Hemming
, B.
, Coatanea
, E.
, Nurmi
, S.
, and Virkkunen
, I.
, 2020
, “Surface Modification of Additively Manufactured 18% Nickel Maraging Steel by Ultrasonic Vibration-Assisted Ball Burnishing
,” ASME J. Manuf. Sci. Eng.
, 142
(7
), p. 071008
. 12.
Zhao
, J.
, Liu
, Z.
, Wang
, B.
, Cai
, Y.
, and Song
, Q.
, 2020
, “Analytical Prediction and Experimental Investigation of Burnishing Force in Rotary Ultrasonic Roller Burnishing Titanium Alloy Ti-6Al-4V
,” ASME J. Manuf. Sci. Eng.
, 142
(3
), p. 031004
. 13.
Liu
, Z.
, Wu
, B.
, Xu
, R.
, and Zhao
, K.
, 2021
, “Grooving of Metals by High-Intensity Focused Ultrasound-Assisted Water-Confined Laser Micromachining
,” ASME J. Manuf. Sci. Eng.
, 143
(9
), p. 091012
. 14.
Lee
, T. H.
, Fan
, H.-T.
, Li
, Y.
, Shriver
, D.
, Arinez
, J.
, Xiao
, G.
, and Banu
, M.
, 2020
, “Enhanced Performance of Ultrasonic Welding of Short Carbon Fiber Polymer Composites Through Control of Morphological Parameters
,” ASME J. Manuf. Sci. Eng.
, 142
(1
), p. 011009
. 15.
Zhang
, J.
, Long
, Z.
, Wang
, C.
, Zhao
, H.
, and Li
, Y.
, 2020
, “Compensation Modeling and Optimization on Contactless Rotary Transformer in Rotary Ultrasonic Machining
,” ASME J. Manuf. Sci. Eng.
, 142
(10
), p. 101001
. 16.
Tawakoli
, T.
, and Azarhoushang
, B.
, 2008
, “Influence of Ultrasonic Vibrations on Dry Grinding of Soft Steel
,” Int. J. Mach. Tools Manuf.
, 48
(14
), pp. 1585
–1591
. 17.
Yang
, Z.
, Zhu
, L.
, Zhang
, G.
, Ni
, C.
, and Lin
, B.
, 2020
, “Review of Ultrasonic Vibration-Assisted Machining in Advanced Materials
,” Int. J. Mach. Tools Manuf.
, 156
, p. 103594
. 18.
Guo
, C.
, Shi
, Z.
, Mullany
, B.
, Linke
, B.
, Yamaguchi
, H.
, Chaudhari
, R.
, Hucker
, S.
, and Shih
, A.
, 2020
, “Recent Advancements in Machining With Abrasives
,” ASME J. Manuf. Sci. Eng.
, 142
(11
), p. 110810
. 19.
Ding
, K.
, Fu
, Y.
, Su
, H.
, Gong
, X.
, and Wu
, K.
, 2014
, “Wear of Diamond Grinding Wheel in Ultrasonic Vibration-Assisted Grinding of Silicon Carbide
,” Int. J. Adv. Manuf. Technol.
, 71
(9
), pp. 1929
–1938
. 20.
Awale
, A. S.
, Srivastava
, A.
, Vashista
, M.
, and Khan Yusufzai
, M. Z.
, 2018
, “Influence of Minimum Quantity Lubrication on Surface Integrity of Ground Hardened H13 Hot Die Steel
,” Int. J. Adv. Manuf. Technol.
, 100
(1
), pp. 983
–997
. 21.
Chaudhari
, A.
, Sharma
, A.
, Awale
, A. S.
, Yusufzai
, M. Z. K.
, and Vashista
, M.
, 2021
, “Effect of Ultrasonic Vibration Assisted Dry Grinding on Hysteresis Loop Characteristics of AISI D2 Tool Steel
,” Sadhana - Acad. Proc. Eng. Sci.
, 46
(4
), pp. 1
–12
. 22.
Bhaduri
, D.
, Soo
, S. L.
, Aspinwall
, D. K.
, Novovic
, D.
, Harden
, P.
, Bohr
, S.
, and Martin
, D.
, 2012
, “A Study on Ultrasonic Assisted Creep Feed Grinding of Nickel Based Superalloys
,” Procedia CIRP
, 1
(1
), pp. 359
–364
. 23.
Tawakoli
, T.
, Azarhoushang
, B.
, and Rabiey
, M.
, 2008
, “Effects of Ultrasonic Vibration on Grinding of 100Cr6
,” Int. J. Mechatron. Manuf. Syst.
, 1
(4
), pp. 332
–342
. 24.
Sun
, G.
, Zhao
, L.
, Ma
, Z.
, and Zhao
, Q.
, 2018
, “Force Prediction Model Considering Material Removal Mechanism for Axial Ultrasonic Vibration-Assisted Peripheral Grinding of Zerodur
,” Int. J. Adv. Manuf. Technol.
, 98
(9–12
), pp. 2775
–2789
. 25.
Paknejad
, M.
, Abdullah
, A.
, and Azarhoushang
, B.
, 2017
, “Effects of High Power Ultrasonic Vibration on Temperature Distribution of Workpiece in Dry Creep Feed up Grinding
,” Ultrason. Sonochem.
, 39
(2
), pp. 392
–402
. 26.
Li
, D.
, Tang
, J.
, Chen
, H.
, and Shao
, W.
, 2019
, “Study on Grinding Force Model in Ultrasonic Vibration-Assisted Grinding of Alloy Structural Steel
,” Int. J. Adv. Manuf. Technol.
, 101
(5–8
), pp. 1467
–1479
. 27.
Abdullah
, A.
, Sotoodezadeh
, M.
, Abedini
, R.
, and Fartashvand
, V.
, 2013
, “Experimental Study on Ultrasonic Use in Dry Creep-Feed Up-grinding of Aluminum 7075 and Steel X210Cr12
,” Int. J. Precis. Eng. Manuf.
, 14
(2
), pp. 191
–198
. 28.
Cao
, J.
, Wu
, Y.
, Li
, J.
, and Zhang
, Q.
, 2016
, “Study on the Material Removal Process in Ultrasonic-Assisted Grinding of SiC Ceramics Using Smooth Particle Hydrodynamic (SPH) Method
,” Int. J. Adv. Manuf. Technol.
, 83
(5–8
), pp. 985
–994
. 29.
Öpöz
, T. T.
, and Chen
, X.
, 2012
, “Experimental Investigation of Material Removal Mechanism in Single Grit Grinding
,” Int. J. Mach. Tools Manuf.
, 63
, pp. 32
–40
. 30.
Zhao
, J. Y.
, Fu
, Y. C.
, Xu
, J. H.
, Tian
, L.
, and Yang
, L.
, 2014
, “Forces and Chip Morphology of Nickel-Based Superalloy Inconel 718 During High Speed Grinding With Single Grain
,” Key Eng. Mater.
, 589–590
, pp. 209
–214
. 31.
Feng
, B. F.
, Cai
, G. Q.
, and Sun
, X. L.
, 2006
, “Groove, Chip and Force Formation in Single Grain High-Speed Grinding
,” Key Eng. Mater.
, 304–305
, pp. 196
–200
. 32.
Fu
, D.
, Ding
, W.
, Miao
, Q.
, and Xu
, J.
, 2017
, “Simulation Research on the Grinding Forces and Stresses Distribution in Single-Grain Surface Grinding of Ti-6Al-4V Alloy When Considering the Actual Cutting-Depth Variation
,” Int. J. Adv. Manuf. Technol.
, 91
(9–12
), pp. 3591
–3602
. 33.
Sinha
, M. K.
, Ghosh
, S.
, and Paruchuri
, V. R.
, 2019
, “Modelling of Specific Grinding Energy for Inconel 718 Superalloy
,” Proc. Inst. Mech. Eng. B
, 233
(2
), pp. 443
–460
. 34.
Liu
, G.
, Dang
, J.
, Chen
, Y.
, Dong
, D.
, and An
, Q.
, 2019
, “Numerical and Experimental Investigation on Grinding-Induced Exit Burr Formation
,” Int. J. Adv. Manuf. Technol.
, 103
(5–8
), pp. 2331
–2346
. 35.
Sagar
, C. K.
, Priyadarshini
, A.
, Gupta
, A. K.
, Kumar
, T.
, and Saxena
, S.
, 2021
, “An Alternate Approach to SHPB Tests to Compute Johnson-Cook Material Model Constants for 97 WHA at High Strain Rates and Elevated Temperatures Using Machining Tests
,” ASME J. Manuf. Sci. Eng.
, 143
(2
), p. 021004
. 36.
Dai
, J.
, Ding
, W.
, Zhang
, L.
, Xu
, J.
, and Su
, H.
, 2015
, “Understanding the Effects of Grinding Speed and Undeformed Chip Thickness on the Chip Formation in High-Speed Grinding
,” Int. J. Adv. Manuf. Technol.
, 81
(5
), pp. 995
–1005
. 37.
Brinksmeier
, E.
, Aurich
, J. C.
, Govekar
, E.
, Heinzel
, C.
, Hoffmeister
, H.-W.
, Klocke
, F.
, Peters
, J.
, et al, 2006
, “Advances in Modeling and Simulation of Grinding Processes
,” CIRP Ann.
, 55
(2
), pp. 667
–696
. 38.
Tönshoff
, H. K.
, Peters
, J.
, Inasaki
, I.
, and Paul
, T.
, 1992
, “Modelling and Simulation of Grinding Processes
,” CIRP Ann.
, 41
(2
), pp. 677
–688
. 39.
Öpöz
, T.
, and Chen
, X.
, 2010
, “Numerical Simulation of Single Grit Grinding
,” Proceeding of the 16th International Conference on Automation & Computing
, Birmingham, UK
, Sept. 11
.40.
Farhadi
, A.
, Abdullah
, A.
, Zarkoob
, J.
, and Pak
, A.
, 2010
, “Analytical and Numerical Simulation of Ultrasonic Assisted Grinding
,” Proceedings of the ASME 2010 10th Biennial Conference on Engineering Systems Design and Analysis
, Istanbul, Turkey
, July 12–14
, Vol. 4, pp. 763
–768
.41.
Khan
, A. M.
, Jamil
, M.
, Mia
, M.
, Pimenov
, D. Y.
, Gasiyarov
, V. R.
, Gupta
, M. K.
, and He
, N.
, 2018
, “Multi-objective Optimization for Grinding of AISI D2 Steel With Al2O3 Wheel Under MQL
,” Materials
, 11
(11
), p. 2269
. 42.
Ribeiro
, F. S.
, Lopes
, J. C.
, Garcia
, M. V.
, de Angelo Sanchez
, L. E.
, de Mello
, H. J.
, de Aguiar
, P. R.
, and Bianchi
, E. C.
, 2020
, “Grinding Assessment of Workpieces with Different Interrupted Geometries Using Aluminum Oxide Wheel With Vitrified Bond
,” Int. J. Adv. Manuf. Technol.
, 108
(3
), pp. 931
–941
. 43.
Sinha
, M. K.
, Madarkar
, R.
, Ghosh
, S.
, and Rao
, P. V.
, 2017
, “Application of Eco-friendly Nanofluids During Grinding of Inconel 718 Through Small Quantity Lubrication
,” J. Cleaner Prod.
, 141
, pp. 1359
–1375
. 44.
Moretti
, G. B.
, Ávila
, B. N.
, Lopes
, J. C.
, de Moraes
, D. L.
, Garcia
, M. V.
, Ribeiro
, F. S. F.
, de Mello
, H. J.
, Sanchez
, L. E. D. A.
, Aguiar
, P. R.
, and Bianchi
, E. C.
, 2021
, “Industrial Manufacturing Linked to the Mechanical and Economic Viewpoint of the Mold Steel Grinding Process Using Aluminum Oxide Wheel
,” Int. J. Adv. Manuf. Technol.
, 117
(9–10
), pp. 2655
–2666
. 45.
Yan
, L.
, Rong
, Y. M.
, Jiang
, F.
, and Zhou
, Z. X.
, 2010
, “Three-Dimension Surface Characterization of Grinding Wheel Using White Light Interferometer
,” Int. J. Adv. Manuf. Technol.
, 55
(1
), pp. 133
–141
. 46.
Nie
, Z.
, Wang
, G.
, Jiang
, F.
, Lin
, Y.
, and Rong
, Y.
, 2018
, “Investigation of Modeling on Single Grit Grinding for Martensitic Stainless Steel
,” J. Cent. South Univ.
, 25
(8
), pp. 1862
–1869
. 47.
Johnson
, G. R.
, and Cook
, W. H.
, 1985
, “Fracture Characteristics of Three Metals Subjected to Various Strains, Strain Rates, Temperatures and Pressures
,” Eng. Fract. Mech.
, 21
(1
), pp. 31
–48
. 48.
Becze
, E. C.
, 2002
, “A Thermo-Mechanical Force Model for Machining Hardened Steel
,” Doctoral dissertation
, McMaster University
, Hamilton, Ontario, Canada
.49.
Wang
, F.
, Tao
, Q.
, Xiao
, L.
, Hu
, J.
, and Xu
, L.
, 2018
, “Simulation and Analysis of Serrated Chip Formation in Cutting Process of Hardened Steel Considering Ploughing-Effect
,” J. Mech. Sci. Technol.
, 32
(5
), pp. 2029
–2037
. 50.
Özel
, T.
, 2009
, “Computational Modelling of 3D Turning: Influence of Edge Micro-geometry on Forces, Stresses, Friction and Tool Wear in PcBN Tooling
,” J. Mater. Process. Technol.
, 209
(11
), pp. 5167
–5177
. 51.
Vyas
, A.
, and Shaw
, M. C.
, 1999
, “Mechanics of Saw-Tooth Chip Formation in Metal Cutting
,” ASME J. Manuf. Sci. Eng.
, 121
(2
), pp. 163
–172
. 52.
Chaudhari
, A.
, Awale
, A. S.
, and Chakrabarti
, A. K.
, 2019
, “Surface Integrity Characterization of Austenitic, Martensitic and Ferritic Stainless Steel Under Different Grinding Process
,” Mater. Res. Express
, 6
(11
), p. 1165c9
. 53.
Li
, S.
, Wu
, Y.
, Fujimoto
, M.
, and Nomura
, M.
, 2016
, “Improving the Working Surface Condition of Electroplated Cubic Boron Nitride Grinding Quill in Surface Grinding of Inconel 718 by the Assistance of Ultrasonic Vibration
,” ASME J. Manuf. Sci. Eng.
, 138
(7
), p. 071008
. 54.
Rowe
, W. B.
, Morgan
, M. N.
, Batako
, A.
, and Jin
, T.
, 2003
, “Energy And Temperature Analysis in Grinding
,” WIT Trans. Eng. Sci.
, 44
, p. 588
. 55.
Kato
, T.
, and Fujii
, H.
, 2000
, “Temperature Measurement of Workpieces in Conventional Surface Grinding
,” ASME J. Manuf. Sci. Eng.
, 122
(2
), pp. 297
–303
. 56.
Zhang
, L.
, and Brian Rowe
, W.
, 2020
, “Study of Convective Heat Transfer in Grinding Applied to Tool Carbide
,” ASME J. Manuf. Sci. Eng.
, 142
(2
), p. 021001
. 57.
Zhang
, L.
, and Brian Rowe
, W.
, 2021
, “Fluid Convection Models for Low-Temperature Grinding and Effect of Fluid Warming
,” ASME J. Manuf. Sci. Eng.
, 143
(2
), p. 021010
. 58.
Nath
, C.
, and Rahman
, M.
, 2008
, “Effect of Machining Parameters in Ultrasonic Vibration Cutting
,” Int. J. Mach. Tools Manuf.
, 48
(9
), pp. 965
–974
. 59.
Dieter
, G.
, and Bacon
, D.
, 1976
, Mechanical Metallurgy
, McGraw-Hill
, New York
.Copyright © 2022 by ASME
You do not currently have access to this content.
