Micro-Grinding Parameter Control of Hard and Brittle Materials Based on Kinematic Analysis of Material Removal

Abstract

This article explores the intricacies of micro-grinding parameter control for hard and brittle materials, with a specific focus on Zirconia ceramics (ZrO2) and Optical Glass (BK7). Given the increasing demand and application of these materials in various high-precision industries, this study aims to provide a comprehensive kinematic analysis of material removal during the micro-grinding process. According to the grinding parameters selected to be analyzed in this study, the ac-max values are between (9.55 nm ~ 67.58 nm). Theoretical modeling of the grinding force considering the brittle and ductile removal phase, frictional effects, the possibility of grit to cut materials, and grinding conditions is very important in order to control and optimize the surface grinding process. This research introduces novel models for predicting and optimizing micro-grinding forces effectively. The primary objective is to establish a micro-grinding force model that facilitates the easy manipulation of micro-grinding parameters, thereby optimizing the machining process for these challenging materials. Through experimental investigations conducted on Zirconia ceramics, the paper evaluates a mathematical model of the grinding force, highlighting its significance in predicting and controlling the forces involved in micro-grinding. The suggested model underwent thorough testing to assess its validity, revealing an accuracy with average variances of 6.616% for the normal force and 5.752% for the tangential force. Additionally, the study delves into the coefficient of friction within the grinding process, suggesting a novel frictional force model. This model is assessed through a series of experiments on Optical Glass BK7, aiming to accurately characterize the frictional forces at play during grinding. The empirical results obtained from both sets of experiments—on Zirconia ceramics and Optical Glass BK7—substantiate the efficacy of the proposed models. These findings confirm the models’ capability to accurately describe the force dynamics in the micro-grinding of hard and brittle materials. The research not only contributes to the theoretical understanding of micro-grinding processes but also offers practical insights for enhancing the efficiency and effectiveness of machining operations involving hard and brittle materials.