Optimization of process parameters of ultrasonic‐assisted end face grinding of C f /SiC composites

Abstract Carbon fiber–reinforced ceramic matrix (C f /SiC) composites are featured with high strength, high‐temperature resistant, and low density, and become an important candidate thermal structural material for the hot end components of high‐performance aero‐engines. Due to their properties of hardness, brittleness, inhomogeneity, and anisotropy, ultrasonic‐assisted grinding is a commonly used method to process C f /SiC composites. The complex nonlinear mapping relationship between ultrasonic‐assisted grinding machining parameters and machining quality of C f /SiC composites needs to be clarified. The Taguchi L16 orthogonal array method was used to carry out ultrasonic‐assisted end grinding experiment of C f /SiC composites in the paper. Combined with the response surface method, the prediction models of surface roughness and grinding force were established, and the prediction of the models was more than 95%. The experimental results were analyzed by signal‐to‐noise ratio analysis, variance analysis, and response surface method. The effects of spindle speed, feed rate, grinding depth, and ultrasonic amplitude on grinding force and surface roughness were investigated. The influence of machining parameters on grinding force and surface roughness was obtained. Finally, the genetic‐particle swarm algorithm was used to optimize the prediction models under different grinding force weights, respectively, and the optimal machining parameters were obtained.