Effects of material properties on texturing of mold materials using ultrasonic-assisted grinding and the machining mechanism of grinding grooves

Abstract

The purpose of this study is to create micro-texture on the surface of various mold materials by ultrasonic-assisted grinding. The effects of materials properties (hardness and fracture toughness) on micro-periodic structure were investigated by performing ultrasonic-assisted grinding, in which ultrasonic vibration is assisted in the axial direction of the grinding wheel in surface plunge grinding. The results showed that periodic structures can be formed without plastic flow on the surface after machining only in the case of cemented carbide with high hardness and low toughness. Furthermore, by modeling the abrasive grain shape and arrangement of the general purpose diamond grinding wheel without special treatment used in the experiments, we attempted to simulate the grinding groove shape formed by a multi-grain grinding wheel when ultrasonic vibration is assisted. The periodic structure formed on the cemented carbide surface was compared with the simulation results, which were in good agreement in terms of the period of the sinusoidal wave and the width of the grinding groove, confirming the validity of this simulation method. From the above, basic knowledge about the machining mechanism of grinding groove in ultrasonic-assisted grinding was obtained.

Keywords

• texturing
• ultrasonic-assisted grinding
• mold materials
• grinding groove
• material properties