Study On Ultrasonic Grinding Mechanism Of Superalloy

Superalloy is widely used in various fields because of its fine physicochemical properties. However, there is a difficult problem how to process it effectively. In order to solve this problems, ultrasonic vibration assisted grinding approach is applied. Ultrasonic vibration machining technology is a new type technology which is applied to grinding process and has some fine superiority in processing super-hard-materials, composite materials and difficult-to-cut materials. Therefore, ultrasonic vibration assisted grinding technology used in superalloy processing open up a new way of difficult-to-cut materials.In this paper, Superalloy GH536as the study object, do study the mechanism of ultrasonic grinding and surface processing quality. The following content is researched:(1) Based on some information about horn design, the theory analysis and design of the step horn were carried out from the aspect of acoustics. Then the mode analysis and structure analysis of the step horn were conducted by software ANSYS according to vibration theory and finite element method. According to the requirements, the ultrasonic vibration wheel was manufactured.(2) During the Ultrasonic Assisted Grinding process, the material removal is the result of interference between the abrasive grits and workpiece, so it is the theory base of researching the machining characteristics of UAG to analyze the kinematics characteristics between the grinding wheel or abrasive grits and the workpiece. In order to study the correlative movement between the abrasive and the workpiece, the kinematics models of the UAG methods were founded. Based on the models of grinding process, the kinematics characteristics and the relative movement trace between the single abrasive grit and the workpiece were researched, and the correlative geometry parameters were analyzed and calculated.(3) The movement interference paths of abrasive grits were analyzed in the ultrasonic grinding, through the ultrasonic grinding surface texture’s observation experiment, proved that the surface to the mechanism of surface in ultrasonic grinding and the ordinary grinding is entirely different.(4) Referring to the grinding force of the relevant information, the grinding force mathematics models of an abrasive grit in common grinding and the UAG were founded, and the grinding force was studied from the aspect of cutting deforming force. The mathematics models of the cutting deforming force was made by introducing the unit grinding force, Fp, and systemic theory analysis and experimental study of grinding force were made from the grinding parameters.