Empirical formula model and process parameter optimization of two-dimensional ultrasonic-assisted grinding force based on 2.5D-Cf/SiC fiber orientation

Due to the anisotropic characteristic of carbon fiber-reinforced silicon carbide ceramics, the fiber orientation angle significantly affects the grinding force. Therefore, it is important to study the influence rule of different fiber orientations on the grinding force of 2.5D-C_f/SiC composites. To study the comprehensive influence of machine tool parameters and the anisotropy of carbon fiber-reinforced ceramic matrix composites on the grinding force, two-dimensional ultrasonic plane grinding was studied by orthogonal test and single-factor experiment. Based on the multi-exponential fitting analysis method of multiple linear regression equation, the empirical equations of power exponential grinding force prediction model of 2D ultrasonic-assisted grinding and conventional grinding 2.5D-C_f/SiC composites at 0°, 45°, and 90° fiber orientation and considering fiber orientation and ultrasonic amplitude were established, respectively. To verify the empirical formula model in predicting the grinding force of 2.5D-C_f/SiC composites under various fiber orientation angles, the regression equation and regression coefficient of the model were examined. The influence of 2.5D-C_f/SiC grinding parameters on the grinding force was analyzed. The parameters of the grinding force model were optimized based on range analysis and variance analysis, and the optimal process parameter combination was obtained. The results show that the grinding force is negatively correlated with the linear speed and positively correlated with the feed speed and grinding depth within the range of experimental parameters. The maximum reduction of the normal grinding force is 29.78% when the line speed is 10.48 m/s, the feed speed is 100 mm/min, the grinding depth is 50 μm, and along the 45° fiber direction. The optimal grinding parameter combination is a line speed of 23.60 m/s, feed speed of 5 mm/min, and grinding depth of 10 μm along the 0° fiber orientation.