The rotating ultrasonic-assisted grinding (RUAG) experiment of the conical grinding wheel generated the intermittent pit-shaped micro-texture on the surface of the workpiece, reducing thermal damage and improving the lubrication characteristics compared with conventional grinding (CG). To further optimize the surface properties, this paper studied the formation mechanism of micro-texture. This study used as basis the theory that micro-debris volume equals the macroscopic material removal one to establish the mathematical equation of grinding depth. Thereafter, formulas of micro-texture feature parameters, including pit length, pit depth, and texture spacing were deduced. The solved microscopic grinding depth was alternatingly positive and negative, indicating that the alternating separation between the grinding grain and workpiece caused intermittent pits in the grinding. Through response surface analysis (RSA), this paper analyzed the relationships among macroscopic grinding depth, micro-texture feature parameters, and machining parameters (i.e., amplitude, feed rate, and rotational speed). Single-factor experiments of machining parameters, with finite element simulation and experiment methods, were performed to verify the theoretical micro-texture features. The simulated program formed three-dimensional surfaces with micro-textures. Their measurement results were consistent with the theoretical ones. Experimental results proved that the range of pit length covers the theoretical ones, further verifying the accuracy of the grinding depth model. For this grinding wheel, the 8–10 μm amplitude was optimal for better roughness, lubrication, and thermal damage. Roughness was improved when increasing the rotational speed or reducing the feed rate based on the experiment. If the rotational speed and feed rate exceed the limiting values, then continuous grinding will break down the abrasive grains and even damage the cubic boron nitride (CBN) coating. Experimental results likewise showed that the pit shape was closely related to the surface properties, which deserves further investigation.

Because the tooth surface micromorphology affects the performance of the gear and the finite element analysis and the grinding process of tooth surface through finite element analysis and simulation is complicated and time-consuming, the paper proposed a three-dimensional (3D) ultrasonic assistant grinding (RUAG) geometric simulation method to discover the micromorphology formation mechanism. Based on the motion path of a single grain, the 3D models of gear blank and the grinder was built. It helps to simulate the RUAG process. The morphologies of the simulated tooth surface were compared under conventional grinding (CG) and RUAG, which was consistent with the practice. It is proved that the geometric simulation method intuitively shows the micro dents on the tooth surface under different grinding parameters. The simulation method is helpful to analyze the surface morphology under different RUAG machining parameters and saves the cost and time of the actual production and processing.