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<p>Alumina is an advanced ceramic material that has numerous applications in dentistry and medicine. Ultrasonic-assisted end grinding proved to be one of the most successful and efficient ceramic processing techniques. However, the current state of the art in UAEG of alumina is mostly limited to finishing operations with low material removal rates. In this paper, UAEG is investigated to find the optimum grinding conditions of roughing operations of alumina ceramics. Response Surface Methodology was employed to study all combined effects of the spindle speed, feed rate, depth of cut, and vibration amplitude on the MRR, grinding forces and surface roughness. The surface morphology of the ground surface and the magnitude of the resultant grinding forces were recorded and analyzed for each test. The results showed that the vibration amplitude has the most influential effect on surface roughness with a contribution of 32.08%, while the grinding force is most affected by depth of cut (32.02%).&#xa0;The spindle speed of 9500&#xa0;rpm, feed rate of 900&#xa0;mm/min, depth of cut of 47&#xa0;µm, and vibration amplitude of 2.6&#xa0;µm are found to be the optimum machining parameters that maximize MRR and minimizing the grinding force and surface roughness.</p> Graphical abstract <p></p>

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Statistical modeling and optimization of ultrasonic vibration assisted end grinding of alumina ceramics

  • 期刊论文

  • 发表日期：

    2025年4月14日

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  • Mohamed M. Mansour,
  • Ibrahem Maher,
  • M. G. A. Nassef,
  • Hassan El-Hofy,
  • Jiwang Yan,
  • W. M. Khairaldien

摘要

Alumina is an advanced ceramic material that has numerous applications in dentistry and medicine. Ultrasonic-assisted end grinding proved to be one of the most successful and efficient ceramic processing techniques. However, the current state of the art in UAEG of alumina is mostly limited to finishing operations with low material removal rates. In this paper, UAEG is investigated to find the optimum grinding conditions of roughing operations of alumina ceramics. Response Surface Methodology was employed to study all combined effects of the spindle speed, feed rate, depth of cut, and vibration amplitude on the MRR, grinding forces and surface roughness. The surface morphology of the ground surface and the magnitude of the resultant grinding forces were recorded and analyzed for each test. The results showed that the vibration amplitude has the most influential effect on surface roughness with a contribution of 32.08%, while the grinding force is most affected by depth of cut (32.02%). The spindle speed of 9500 rpm, feed rate of 900 mm/min, depth of cut of 47 µm, and vibration amplitude of 2.6 µm are found to be the optimum machining parameters that maximize MRR and minimizing the grinding force and surface roughness.

Graphical abstract