Optimization of Boundary Damage Length in Ultrasonic Vibration Assisted Electrolytic in-Process Dressing Internal Grinding of ZTA Ceramics by Response Surface Methodology

Abstract

Abstract: Experiment of ultrasonic vibration assisted electrolytic in-process dressing internal (UAEI) grinding for zirconia toughened alumina (ZTA) ceramics was carried out based on Box-Behnken design method of response surface methodology, and response surface model was established. The influence law of four process parameters of electrolytic in-process dressing (ELID) power supply voltage, grinding depth, axial feed and wheel speed and their interaction on the boundary damage length was studied through significance test, response surface plot and contour map obtained from experiments. The influence intensity of significant factors on response value was obtained by analyzing the response surface plot and contour map obtained from response surface model, and the cause of the interaction influence on response value was also analyzed. The influence intensity of significant factors on response value in descending order are grinding depth, ELID power supply voltage, axial feed and wheel speed. The influence intensity of interaction of factors combination on the response value in descending order are interaction between grinding depth and grinding wheel speed, interaction between axial feed and grinding wheel speed, interaction between ELID power supply voltage and grinding depth, interaction between grinding depth and axial feed. Taking the minimum boundary damage length as the optimization objective, the optimal combination of parameters of UAEI grinding for ZTA ceramics are as follows: ELID power supply voltage is 86.39 V, grinding depth is 1.55 μm, axial feed is 81.24 mm/min, wheel speed is 2 741.41 r/min, and the theoretical prediction value of optimal boundary damage length is 6.537 μm. The relative error is within a reasonable range by experimental verification. The response surface model has a higher precision and provides some reference for reasonable selection of process parameters of UAEI grinding.

Key words: response surface methodology, ZTA ceramics, ultrasonic vibration assisted ELID internal grinding, boundary damage length, experimental verification

CLC Number:

TQ174.75⁺8.11

JIA Xiaofeng, LIU Yuhui. Optimization of Boundary Damage Length in Ultrasonic Vibration Assisted Electrolytic in-Process Dressing Internal Grinding of ZTA Ceramics by Response Surface Methodology[J]. JOURNAL OF SYNTHETIC CRYSTALS, 2021, 50(5): 938-946.

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