This study proposes the mechanism of two-dimensional ultrasonic assisted grinding- electrolysis-discharge generating machining (2UG-E-DM). It analyzed the influence of vibration directions on grinding characteristics and surface morphology through the motion simulation of an abrasive. Comparative experiments with different vibration directions verified the effect of ultrasonic assistance on the weakening of the grinding force, the widening of the surface pits, and the leveling of the surface morphology of SiCp/Al composites. Simulation analysis of a single abrasive particle verified the test results. The results of machining tests at different amplitudes showed that as the workpiece and tool amplitude increased, the grinding force of the normal force decreased faster than that of the tangential force. The effect of surface electrolysis discharge machining was significant, and the number of exposed particles increased, but the residual height of the surface and the surface roughness were reduced by vibration grinding. When the two-dimensional amplitude was increased to 5 μm, the axial and tangential vibrations increased the grinding domain, and the dragging and rolling of the reinforced particles significantly reduced the surface roughness, which obtained good surface quality.
Keywords: grinding electrolysis discharge; grinding force; surface roughness; vibration direction.