Tool-Workpiece Interaction in Ultrasonic-assisted Grinding

• Applicant: Professor Dr.-Ing. Eckart Uhlmann
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2016
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 326610871

The continuous development of materials with improved mechanical and thermal properties, but also the need for increased productivity in relation to process times, require optimised manufacturing methods and an adaptation of machining technology. Due to the excellent and constantly improved properties there is a high demand for such technologies in the field of high-performance ceramics. These highly hard and wear-resistant technical ceramics can be given a high degree of toughness through innovative material optimization. However, this poses great challenges for hard fine machining in terms of increasing machining forces and tool loads. Brittle cutting mechanisms can be induced by suitable process parameters, resulting in generally lower process forces compared to ductile machining. As an indicator for the chip formation mechanisms the critical chip thickness according to Bifano is often used to characterize the grinding process. A high material toughness results in a higher value for the critical chip thickness which makes machining much more difficult due to the high individual grain forces required for the brittle separation mechanisms. One possibility to influence the critical chip thickness advantageously is to superimpose the kinematics of the grinding process with an ultrasonic movement. The main objective of the project is therefore to investigate the influence of the actual ultrasonic amplitude on the grinding process parameters and the grinding result as well as the associated reliable application of ultrasonic-supported grinding technology in ceramic machining. While in the first funding period the focus was initially only on non-conditionable electroplated grinding tools, the second funding period will focus on the comparison of commercially available grinding tools with conditionable abrasive coatings.

• DFG Programme: Research Grants