Research on surface damage during ultrasonic vibration-assisted single abrasive grinding of WC-10Co-4C coatings

WC-based cemented carbide coatings, fabricated via supersonic flame spraying, exhibit excellent density and high bonding strength with substrates, making them widely applicable as wear-resistant coatings in aero-engines. However, their high hardness and wear resistance often lead to crack formation during grinding, which compromises coating longevity. Ultrasonic vibration-assisted grinding (UVAG) has shown promising results in processing various materials with high hardness and brittleness, yet its impact on surface damage in cemented carbide coatings remains unclear. This study investigates the influence of single-grit cutting thickness and grinding speed on the grinding-induced damage of WC-10Co-4Cr coatings. The results demonstrate that the single-grit grinding forces in UVAG exhibits a consistent reduction in forces relative to conventional grinding. Specifically, the normal grinding force decreases by 4.4–47.8%, and the tangential grinding force drops by 16.7–32.2% compared to traditional grinding. The surface profile of UVAG-processed grooves is smoother, with shallower micro-grooves and reduced numbers and magnitudes of surface protrusions and depressions. UVAG yields superior surface quality compared to conventional grinding, with surface damage primarily characterized by minor fractures and cracks.