Grinding force assessment in tangential ultrasonic vibration-assisted grinding gear: Analytical model and experimental verification

Tangential ultrasonic vibration-assisted grinding gear (TUVAGG) is a new promising process combining the ultrasonic vibration with conventional grinding gear (CGG). In this study, an assessment of grinding forces from the point of theoretical and experimental was provided in TUVAGG, revealing its mechanism. Therefore, a prediction model of abrasive grain force was established based on the micro-removal mechanism of materials under ultrasonic vibration. First, the motion characteristics of a single abrasive grain were investigated in TUVAGG. Then, taking into account the two stages of the material removal mechanism, the grinding force model of the plowing stage and cutting stage is determined. Finally, TUVAGG experiments were performed to verify the developed model and to determine that the predicted results coincide with the experimental ones. The grinding force decreases with the increase in spindle speed and ultrasonic amplitude, but increases with the increase in feed speed and radial grinding depth. The prediction and experimental results show that the maximum difference between normal and tangential grinding forces is 12.63 and 14.82%, respectively. The developed model provides a deeper insight into the TUVAGG mechanism and a reference for practical technical applications.