Study on motion trajectory and grinding force of graphene toughened ZrB2 ceramic matrix composites by two-dimensional ultrasonic assisted grinding

The grinding force serves as a crucial indicator for assessing the effectiveness of the grinding. Analysis and modelling of grinding forces provides insight into the material removal mechanism and surface quality of graphene toughened ZrB₂ ceramic matrix composites. However, there are relatively few researches on the grinding force of the composites by two-dimensional ultrasonic assisted grinding. In this study, the real-time cutting depth and cutting range of abrasive particles in two-dimensional ultrasonic assisted grinding are analyzed, and the cutting trajectory equation of a single abrasive particle is established considering the real-time cutting depth and cutting range of abrasive particles. On this basis, the influence of critical cutting depth and maximum undeformed chip thickness on the material removal mechanisms of graphene-enhanced ZrB₂ ceramic composites is examined. At the same time, grinding force models for plastic and brittle removal in two-dimensional ultrasonic-assisted grinding are also established. Finally, the model’s accuracy is confirmed, and the impact of two-dimensional ultrasonic grinding parameters on grinding forces is evaluated. The results reveal that higher feed rates and deeper grinding depths lead to increased grinding forces, while greater grinding speeds and larger ultrasonic amplitudes result in reduced grinding forces. The average relative error of normal grinding force is 8.39%, and that of tangential grinding force is 9.98%. The experimental data aligns well with the predicted trends in grinding forces.