Study on surface creation law of planar two-dimensional ultrasonic-assisted abrasive belt grinding

A possible solution for grinding hard-to-machine materials, including nickel-based high-temperature alloys, is ultrasonic vibration-assisted grinding (UVG). In this paper, based on the kinematics analysis of elliptical ultrasonic vibration assisted grinding (EUVG), the grinding morphology simulation models under different processes are constructed and the grinding surface roughness is calculated. The influence of ultrasonic vibration amplitude and feed speed on the grinding surface quality of EUVG is explored. According to the findings, EUVG has a special grinding surface topography that can provide refinement and interruption effects on the surface texture as well as a considerable reduction in grinding surface roughness of up to 27.7%. The increase of axial (perpendicular to the feed direction) and tangential (along the feed direction) amplitude can reduce the surface roughness, and the axial amplitude has a greater influence on the roughness. The tangential amplitude refines the surface on the basis of retaining the intermittent texture features generated by the axial vibration to obtain a smoother surface. With the increase of feed speed, the interval distance of grinding surface texture increases, the surface finish decreases and the roughness increases. Finally, the reliability of the model is verified by single grain and abrasive belt grinding experiments. It provides a theoretical basis for exploring the optimization of high-quality processing parameters of GH4169 superalloy EUVG.