Geometrical transcription of diamond electroplated tool in ultrasonic vibration assisted grinding of steel

Application of diamond electroplated tool (DET) to ultrasonic vibration assisted grinding (UVAG) of steel surface for mirror finish has been introduced, but the effect of DET working surface topography to the work roughness has not been clarified. The objectives of this study are to parameterize the DET based on the quantity and distribution of the active grains, and then to make clear how these grains protrusion parameters are related to UVAG performance (i.e., work roughness). In this paper, work roughness is used for the process assessment using characterization condition selected on the basis of the machining condition with white light interferometer as the measuring instrument. Higher magnification measurement on the work surface is performed, revealing the existence of ultrasonic vibration marks with unique constant wavelength for each sample which then is used for the estimation of active grain position. Meanwhile, in order to enable identification of the active grain based on the grain height, the entire DET working surface topography is measured in a single measurement and reversal method based procedure is used to extract the reference datum. The active grain identified from the DET working surface topography has a position similar to the one estimated from the work surface topography indicated the appropriateness of both methods. Simulation and experiment result showed the optimum position of the active grain for smoother work roughness. Furthermore, the multiple active grains with similar locus radius are observed to contribute to less roughness. The information gained in this study can improve the controllability of the UVAG.

► Work roughness can be used to assess the ultrasonic vibration assisted grinding. ► Ultrasonic vibration marks on work topography can be used to estimate one active grain locus. ► Reversal method can be used to extract the reference datum for diamond electroplated tool topography characterization. ► The active grain position and number affect the surface roughness. ► Optimum active grain position exists for given machining condition.