Ultrasonic vibration-assisted grinding of silicon carbide ceramics based on actual amplitude measurement: Grinding force and surface quality

The actual vibration amplitude (AVA) during ultrasonic vibration-assisted face grinding (UVAFG) is an essential parameter that affects grinding force and surface quality. However, an effective method for the real-time measurement of AVA during grinding remains unavailable, hindering research on UVAFG. In this study, an experimental setup for measuring AVA is firstly established using an eddy current sensor. Ultrasonic amplitude curves under the condition of tool rotation without load are measured and analysed. Then, amplitude attenuation with different grinding forces is evaluated during the UVAFG of silicon carbide (SiC) ceramics. The influences of AVA on grinding force and surface quality are investigated through comparative experiments of the UVAFG and conventional grinding (CG) of SiC ceramics. Finally, experimental results indicate that AVA exhibits a negative correlation with grinding force. Compared with CG, UAVFG has lower grinding force when grinding SiC ceramics. AVA is the key factor that affects surface roughness during UVAFG, the AVA of UVAFG is less than 4.3 μm; thus, surface roughness during UAVFG will be less than that during CG. Moreover, vibration can reduce the scratches made by the tools on the grinding surface.