A robust design based methodology for investigation of optimal parameters' combination in ultrasonic assisted face grinding

This manuscript presents the results of experimental investigations which have been carried out to investigate the optimal parameter combination that results in the minimum axial process force (PF) in ultrasonic assisted face grinding (UAFG). A diamond grinding tool (diamond drill) was used in these investigations. The UAFG is a hybrid machining process, which has been used for the machining of advanced ceramic materials. The application of ultrasonic assisted grinding (UAG) is still limited, inter alia, because of difficulties during the selection of values for input machining parameters, such as: cutting velocity, feed rate, frequency of vibrations, and mounting torque, which is applied during tool clamping. The ultrasonic assistance provides advantages for the process course if the appropriate combination of input parameters is set on a hybrid/computer numerical control (CNC) machine tool. The PFs on the Ultrasonic 20 linear machine tool are measured using the Kistler 9256C2 dynamometer, and the optimal process parameter combination is calculated using the engineering robust design approach (ERDA).