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Grinding wheel wear and machining quality in ultrasonic-assisted grinding of threaded holes in Cf/SiC composites.

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Title: Grinding wheel wear and machining quality in ultrasonic-assisted grinding of threaded holes in Cf/SiC composites.
Authors: Sun, Haiqi1 (AUTHOR), Liu, Hanbin1 (AUTHOR), Bao, Yan1 (AUTHOR), Yang, Chen1 (AUTHOR), Dong, Zhigang1 (AUTHOR), Sun, Jiansong1 (AUTHOR) sunjs@dlut.edu.cn
Source: Ceramics International. May2026:Part B, Vol. 52 Issue 13, p22855-22868. 14p.
Subjects: Grinding wheels, Machining, Surface roughness, Ceramic-matrix composites, Diamond wheels, Grinding machines
Abstract: C f /SiC composites are extensively employed in aerospace engineering applications, particularly for manufacturing high-temperature components, owing to their exceptional lightweight properties and superior thermal stability. However, their high hardness, non-homogeneous nature, and low fracture toughness lead to severe wear of the grinding wheel, resulting in poor machining quality and low efficiency. This has become a technical bottleneck for the use of C f /SiC composites in structural components. In this paper, a comparison study was conducted using sintered diamond grinding wheels to examine the wear patterns and machining quality of threaded holes under conventional and ultrasonic-assisted grinding. Continuous threading experiments were systematically performed to investigate four critical grinding parameters: wheel radius wear, profile angle deviation, grain wear morphology, and effective grain protrusion height. Additionally, comprehensive analyses were conducted on burr formation at both entrance and exit zones, along with quantitative evaluations of wall surface roughness and hole dimensional accuracy. The experimental findings demonstrate that ultrasonic-assisted grinding significantly reduces grinding wheel wear: after machining 55 holes, the radius of the grinding wheel decreased by only 2.11% compared to 3.00% with conventional grinding, and the proportion of grain fracture was reduced by 40.6%. Additionally, the burr factor at the entrance and exit of the threaded holes was reduced by 20%, the surface roughness of the hole walls was improved by 17%, and the machining accuracy of the hole diameter was enhanced by 30%. The number of threaded holes that met the specified quality standards increased by 23.7%. Ultrasonic vibrations significantly delay grinding wheel wear and promoting favorable self-sharpening characteristics of the grinding wheel and improving machining quality. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
Description
Abstract:C f /SiC composites are extensively employed in aerospace engineering applications, particularly for manufacturing high-temperature components, owing to their exceptional lightweight properties and superior thermal stability. However, their high hardness, non-homogeneous nature, and low fracture toughness lead to severe wear of the grinding wheel, resulting in poor machining quality and low efficiency. This has become a technical bottleneck for the use of C f /SiC composites in structural components. In this paper, a comparison study was conducted using sintered diamond grinding wheels to examine the wear patterns and machining quality of threaded holes under conventional and ultrasonic-assisted grinding. Continuous threading experiments were systematically performed to investigate four critical grinding parameters: wheel radius wear, profile angle deviation, grain wear morphology, and effective grain protrusion height. Additionally, comprehensive analyses were conducted on burr formation at both entrance and exit zones, along with quantitative evaluations of wall surface roughness and hole dimensional accuracy. The experimental findings demonstrate that ultrasonic-assisted grinding significantly reduces grinding wheel wear: after machining 55 holes, the radius of the grinding wheel decreased by only 2.11% compared to 3.00% with conventional grinding, and the proportion of grain fracture was reduced by 40.6%. Additionally, the burr factor at the entrance and exit of the threaded holes was reduced by 20%, the surface roughness of the hole walls was improved by 17%, and the machining accuracy of the hole diameter was enhanced by 30%. The number of threaded holes that met the specified quality standards increased by 23.7%. Ultrasonic vibrations significantly delay grinding wheel wear and promoting favorable self-sharpening characteristics of the grinding wheel and improving machining quality. [ABSTRACT FROM AUTHOR]
ISSN:02728842
DOI:10.1016/j.ceramint.2026.03.343