Modeling and analysis of grinding force in ultrasonic honing considering the scale effect

To research the power ultrasonic honing mechanism at the micro scale, the scale effect is considered and the strain gradient plasticity theory based on the dislocation mechanism (MSG) is applied to establish the model of a whetstone grinding force, and the simulation analysis is conducted. Results show: the grinding force will increase when the scale effect is considered; the main influence parameter is honing depth on the grinding force; the grinding force increases nonlinearly with the continued reduce of honing depth after which decreases to 1.4 μm, which decreases slightly with the increase of the relative velocity of a whetstone. So the material becomes difficult to remove at the micro scale.