Investigation of intermittent cutting mechanism of abrasive particles in ultrasonic-assisted external cylindrical honing

Ultrasonic-assisted honing, which is a finishing grinding method, has been considered effective for improving the cutting performance of abrasive particles. However, the effect mechanism of the ultrasonic vibration on the cutting process of abrasive particles has not yet been clarified, which hinders the application and development of this technology. In this study, new kinematics and cutting process models of a single abrasive particle in ultrasonic-assisted external cylindrical honing (UAECH) were established. The parameters and interruption conditions affecting the intermittent cutting process of the abrasive particle were clarified based on the coupling effect of ultrasonic vibration and rotation of workpiece. Finite element simulation analysis has revealed that the increases in ultrasonic frequency and amplitude can reduce the interruption threshold and cutting time proportion in the intermittent cutting process of abrasive particles mainly by increasing the relative velocity of abrasive particles. Furthermore, for the cutting depth and rotation speed, their influence on the intermittent cutting process is mainly based on the change of the deformation rate of workpiece material. Moreover, it was found that there was counteraction effect between the tangential forces on the symmetrical surfaces of the abrasive particle in UAECH, which can help reduce the tangential honing force and improve the honing performance. The experimental results demonstrated a significant improvement in the average tangential honing force in UAECH and novel dents surface topography, which can provide guidance for the application of ultrasonic vibration in the grinding field and development of forming processes for functional surface topography in honing.