A mechanical model of cutting force in end surface grinding of zirconia ceramics using rotary ultrasonic machining with longitudinal-torsional coupled vibration.

Longitudinal-torsional coupled vibration rotary ultrasonic machining (LTC-RUM) provides effective surface grinding of difficult-to-machine and brittle materials. The cutting force analysis can assess its machining effect, which is instrumental in further exploring the material removal mechanism. This study proposed a cutting force model of LTC-RUM end surface grinding of zirconia ceramics considering the ductile and brittle stage of the material removal. The corresponding single abrasive particle movement, cutting depth, and material removal rate during each stage was analyzed in detail, and the cutting force evolution was predicted. Several designed experiments were conducted, verifying the developed model's feasibility. The predicted and experimental results agreed well under various input variables. The cutting force was reduced by increasing spindle speed and ultrasonic power while it grew with feed rate and cutting depth. [ABSTRACT FROM AUTHOR]