A cutting force prediction model in axial ultrasonic vibration end grinding for BK7 optical glass considering protrusion height of abrasive grits

Abstract Axial ultrasonic vibration end grinding (AUVEG) has been recognized as an efficient machining method for hard and brittle materials. In this paper, a theoretical model was proposed for predicting cutting force in AUVEG of BK7 optical glass with consideration of the nonuniform protrusion height of abrasive grits. Since the protrusion height of diamond grits was closely related to the cutting force, the modelling of the wheel end-face morphologies was performed to obtain the protrusion height information of diamond grits. Based on indention theory combined with energy perspective, a material removal rate model was proposed for establishing the cutting force model. Experiments were conducted to verify the validity of the proposed model, and the mean error between predicted and experimental force is 4.94%. The proposed model could be used in selecting process parameters for realizing high efficiency and precision AUVEG machining of BK7 optical glass.