Surface formation modeling and surface integrity research of normal ultrasonic assisted flexible abrasive belt grinding

A kinematic model of normal ultrasonic assisted abrasive belt grinding (UAABG) considering abrasive belt's flexibility characteristic was established, and the motion characteristics and material removal rules of abrasive grains under ultrasonic vibration assisted were analyzed. The surface formation characteristic of UAABG and the effect of ultrasonic vibration on the surface integrity of GH4169 were explored through UAABG experiments. Results show that the flexible characteristic of abrasive belt adjusts the release process of ultrasonic vibration energy and avoids surface damage. In addition, due to the dynamic change in the number and position of abrasive grains involved in cutting, the surface texture is more disordered. Compared with conventional abrasive belt grinding (CABG), UAABG reduces surface roughness by 25 %, increases the surface residual compressive stress by 110 %, and slightly improves the surface hardness. In addition, surface damages caused by plastic accumulation during continuous material removal are avoided. Consequently, UAABG can be used for highperformance surface machining of GH4169, and it plays an important role in promoting the application and development of ultrasonic vibration-assisted machining technology in the field of abrasive belt grinding.