Prediction modelling of grinding force in ultrasound vibration-assisted end grinding nickel-based alloy Inconel 718

Ultrasound vibration-assisted end grinding (UVEG) of alloy materials has advantages in improving surface mechanical properties and enhancing surface quality. The grinding force is a key parameter for evaluating the cutting performance of abrasive grains and the quality of machined surface. However, modeling of grinding forces in UVEG has not yet been reported in the literature. A predictive model considering the ultrasonic vibration of the end-face abrasive grains and the equivalent cutting depth was proposed. The model was developed through the kinematic analysis of the abrasive grains on the wheel’s end face. It incorporated the length of the grain’s movement trajectory, the equivalent machining depth, material characteristics, and the impact force generated by the periodic motion. The normal and radial components of the force were determined by considering the contributions of chip deformation force and friction force. The accuracy of the model was validated by comparing the numerical simulation results with the experimental data. The developed prediction model elucidated the influence mechanisms of process parameters in UVEG of the nickel-based alloy Inconel 718. This study provides theoretical guidance for investigating the cutting performance and surface quality improvement in UVEG of metallic materials.