Research And Development Of ELID Grinding Technique Assisted With Ultrasonic Vibration

In current machinery fabrication process,high strength,wear resistance,corrosion resistance,high temperature resistant engineering ceramics has been widely used in machinery,automobile,aerospace,electronics,chemical industry,metallurgy,and many other fields.Engineering ceramics with high hardness and brittleness,however,its processing and forming is very difficult and the cost of processing can reach 80% ~ 90% of the entire cost of ceramic element.Therefore,how to efficiently obtain the ultra precision machining surface quality,at the same time can reduce the processing cost is in the field has been the main problem to be solved.The ultrasonic precision machining and ELID mirror grinding technique has been widely applied for precision machining of hard and brittle materials.Even the ELID mirror grinding technique has high machining accuracy,but the machining cost is higher,and machining process is a little difficulty.If the ELID grinding technique combined with ultrasonic vibration would be applied for machining of hard and brittle materials,the ground surface accuracy and the grinding efficiency of the ceramic can effectively improved,even the machining cost can be significantly reduced.In this paper,the main work and achievements are as follows:1.Theoretical studied the ELID grinding process assisted with ultrasonic vibration,based on the analysis of single particle cutting process,established mathematical model of grinding force,under the condition of ultrasonic combined with ELID grinding,discussed ultrasonic influence of ELID grinding force.2.According to the overall design of ultrasonic vibration instrument assisted ELID grinding process,the ultrasonic power,ultrasonic transducer,ultrasonic amplitude and structure design of the ultrasonic vibration table,were analyzed and selected,developed a new ultrasonic vibration instrument to aid ELID grinding process.3.Through the analysis of the vibration modal and harmonic response using of Solidworks and ANSYS software,the simulation of ultrasonic machine process and the amplitude of ultrasonic vibration were carried out,discussed the effect of converted amplitude of vibration table to the amplitude value of the workpieces based on the analysis of the vibration model and natural frequency,verified the results of simulation with the experimental study of the frequency and vibration value of the ultrasonic vibration table.4.Based on established ultrasonic aided ELID grinding system,some ELID grinding factors such as ELID power supply,ultrasonic power supply and the grinding parameters were analyzed to the influence of the tangential grinding force by the experimental study of the ultrasonic aided ELID grinding.In this paper,with the developed ultrasonic vibrstion instrument assisted ELID grinding process,provided an effective new mschining method for ultra-precision machining of hard and brittle materials,the proposed research theory and experiment study would provide an effective theoretical support for the application of this new kind of machining technique in the pricision machining industries.