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Material removal and surface generation mechanisms in rotary ultrasonic vibration–assisted aspheric grinding of glass ceramics

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Abstract

High-efficiency precision grinding can shorten the machining cycle of aspheric optical elements by a factor of 2–10. To achieve this objective, ultrasonic vibration (UV)–assisted grinding (UVG) has been increasingly applied to manufacture aspheric optics. However, the mechanisms of material removal and surface formation in UV-assisted aspheric grinding of glass ceramics have rarely been studied. Herein, rotary UV-assisted vertical grinding (RUVG) was used to explore the machining mechanism of coaxial curved surfaces. First, RUV-assisted scratch experiments were conducted on aspheric surface of glass ceramics, which exhibited multiple benefits over conventional scratching. These include a reduction in the scratch force by 37.83–44.55% for tangential component and 3.87–28.15% for normal component, an increase in plastic removal length by 43.75%, and an increase in material removal rate by almost a factor of 2. Moreover, grinding marks on the aspheric surface in RUVG were accurately simulated and optimized by adjusting grinding parameters. RUVG experiments were performed to verify the accuracy of grinding texture simulations and investigate the UV effect. The results demonstrate that UV can improve the surface quality of aspheric grinding when compared with conventional vertical grinding. In particular, the total height of the profile of form accuracy and its root mean square were significantly improved by a factor of 3.38–4.54 and 7.15–10.82, respectively, and the surface roughness reduced by 10.03–12.10%. This study provides deeper insight into material removal and surface generation mechanisms for RUVG of aspheric surfaces, and it is thus envisaged that these results will be useful in engineering applications.

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Funding

This work was supported by the National Natural Science Foundation of China (NSFC) (grant number 52105493), the Natural Science Basic Research Plan in Shaanxi Province of China (grant number 2023-JC-QN-0713), the Hunan Provincial Natural Science Foundation of China (grant number 2023JJ40670), the Youth Innovation Promotion Association CAS (grant number 2023423), and the China Postdoctoral Science Foundation (grant number 4139ZRY4).

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Authors and Affiliations

  1. Xi’an Institute of Optics and Precision Mechanics, Chinese Academy of Sciences, Xi’an, 710119, China

    Guoyan Sun, Xiabin Ji & Jiaoteng Ding

  2. College of Artificial Intelligence, National University of Defense Technology, Changsha, 410003, China

    Guoyan Sun

  3. Center for Precision Engineering School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Sheng Wang & Qingliang Zhao

Authors
  1. Guoyan Sun
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Contributions

All authors contributed to the study conception and design. Guoyan Sun: conceptualization, writing—original draft preparation. Sheng Wang: writing—original draft preparation; experiments, image processing. Qingliang Zhao: writing—review and editing. Xiabin Ji: data curation. Jiaoteng Ding: measurement and data analysis.

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Correspondence to Sheng Wang.

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Sun, G., Wang, S., Zhao, Q. et al. Material removal and surface generation mechanisms in rotary ultrasonic vibration–assisted aspheric grinding of glass ceramics. Int J Adv Manuf Technol 130, 3721–3740 (2024). https://doi.org/10.1007/s00170-023-12904-x

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  • DOI: https://doi.org/10.1007/s00170-023-12904-x

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