On the tool wear behavior during ultrasonic vibration-assisted form grinding with alumina wheels

Abstract Ultrasonic vibration-assisted form grinding (UVAFG) with alumina wheels has become a potential technology to machine the areo-engine blade root. In this work, the characterizations of wear patterns of grinding wheel surface morphologies, such as clogging, grain micro-fracture and pull-out, were performed under conventional form grinding (CFG) and UVAFG methods, respectively. In addition, the comparative grinding performances, including grinding forces and force ratio, protrusion height distribution of worn grains, ground surface quality for both grinding methods, were discussed. The results indicate that the tool clogging and grain pull-out under UVAFG method can be effectively improved compared to CFG method. More excellent sharpness ability of alumina wheels under UVAFG can be obtained due to the grain micro-fracture by high frequency impacting between tool and workpiece. Furthermore, the alumina wheels under UVAFG possess lower grinding forces, larger protrusion height values of worn grains, and better ground surface quality in comparison of the other grinding method.