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

Abstract

Rotary ultrasonic assisted end grinding (RUAEG) is a new machining process that has attracted numerousresearchers. 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 defor-mation and brittle fracture will be considered that was a novelty of this investigation. Analyses were car-ried out based on indentation fracture theory and Vickers hardness relationships. Afterwards, verificationexperiments demonstrated mean error value of 17.27% between theoretical model and experimental val-ues. Based on the presented model, input machining variables and tool properties variation influence oncutting force were investigated. The present research outcome can be a reliable model to predict cuttingforce more precisely and understand the cutting mechanism in RUAEG. In the following, RUAEG processand conventional end grinding results were compared that was observed in RUAEG, cutting force could bereduced up to 64%.