Mathematical model to predict cutting force in rotary ultrasonic assisted end grinding of Si3N4 considering both ductile and brittle deformation.

• Cutting force model based on both ductile and brittle deformation in RUAEG of Si3N4. • Ultrasonic applying on the tool reduces cutting force up to 64% • Theoretical model trend is in good accordance with the experimental results. Rotary ultrasonic assisted end grinding (RUAEG) is a new machining process that has attracted numerous researchers. This paper presents a theoretical model to predict cutting force in RUAEG of Si3N4 ceramics. Since cutting process includes both ductile deformation and brittle fracture, combination of ductile deformation and brittle fracture will be considered that was a novelty of this investigation. Analyses were carried out based on indentation fracture theory and Vickers hardness relationships. Afterwards, verification experiments demonstrated mean error value of 17.27% between theoretical model and experimental values. Based on the presented model, input machining variables and tool properties variation influence on cutting force were investigated. The present research outcome can be a reliable model to predict cutting force more precisely and understand the cutting mechanism in RUAEG. In the following, RUAEG process and conventional end grinding results were compared that was observed in RUAEG, cutting force could be reduced up to 64%. [ABSTRACT FROM AUTHOR]