Study of Subsurface damage of tungsten alloy in rotary ultrasonic grinding

Abstract

Tungsten alloy is generally used in aerospace, military defense services, the nuclear industry, and other essential fiel ds of manufacturing due to its physical and chemical properties. As the demand for tungsten alloy increases, it dema nds higher requirements for the accuracy, quality, and surface integrity of tungsten alloy products. So, it is of paramo unt importance to study the manufacturing, processing, and testing of tungsten alloys through the power generating du ring machining, the surface, and subsurface of finished products. Grinding is an abrasive machining method that can achieve extremely fine surface finishes while retaining high dimensional and shape precision. However, the process ca uses subsurface damage, which affects the mechanical properties and surface quality of the machined workpiece. In th is paper, the grinding simulations in Abaqus software and experiments on CNC machine on both Rotary Ultrasonic G rinding (RUG) and Conventional Grinding (CG) were carried out by Taguchi experimental design method to study th e different influences of spindle speed, grinding depth, feed rate, ultrasonic frequency and amplitude on subsurface da mage induced in grinding of tungsten alloy. Briefly, simulation and experiment results showed well agreement at the same time present the reduction of subsurface damage depth on ultrasonic grinding compared to conventional grindin g. Also, the increase of grinding depth and feed rate and amplitude generates a high Subsurface Damage depth (SSD depth) where the increasing of spindle speed decreases the SSD depth, but ultrasonic frequency present a little effect on it.