Study on cutting performance of ceramic rock slab machined by rotating ultrasonic vibration.

Ceramic rock slab is a kind of new material with the advantages of high hardness, wear resistance, and high-temperature resistance, and it is widely used in industry and households. However, problems such as easy chipping and serious tool wearing occurred in conventional grinding (CG). To overcome these challenges, this work introduces rotary ultrasonic grinding (RUG) in processing ceramic rock slabs. Study the theoretical motion trajectory of single abrasive grain and the removal mechanism of hard and brittle materials in RUG, and analyzed the influence of amplitude on cutting force in finite element simulation of single abrasive grain. A comparative process experiment of RUG and CG was performed on the hole processing of ceramic rock slabs. The experimental results showed that compared with CG, the cutting force and chipping area of RUG were reduced by 40.4 and 14.3%, respectively. The cutting force and chipping area decreased with the increase of the spindle speed and increased with the increase of the feed speed. With the increase of ultrasonic amplitude, the cutting force and chipping area decreased gradually, and the tool wear rate decreased from 0.54 to 0.10%, which effectively suppresses the spalling of abrasive grains on the surface of the tool and extends the life of the tool. [ABSTRACT FROM AUTHOR]