Controlled vibration amplitude in ultrasonic assisted grinding using FRF guided cutting frequency

In ultrasonic-assisted machining, vibration amplitudes can be controlled at the resonant frequency by altering the ultrasonic power. However, the availability of amplitude controlled ultrasonic power is constrained to limited types of machine tools. The present study introduces a novel idea for generating identified vibration amplitudes for a diamond-grinding tool by adjusting the ultrasonic frequency in the range from 20 kHz to 30 kHz. For this purpose, experimental model analysis (EMA) is carried out on five different diamond-grinding tools to obtain their frequency response function (FRF) curves. The vibration amplitude is measured using a dial indicator and eddy current sensor methods. Further analysis is conducted using 3D laser microscope after machining to decide the proper measurement method. It is found that various amplitudes can be successfully accurately reached from an individual cutting tool by altering the input ultrasonic frequency according to the generated FRF curve of the tool.