Surface characteristics in the ultrasonic ductile honing of ZrO2 ceramics using coarse grits

Experimental research into the surface characteristics in the ultrasonic ductile-regime honing of ZrO2 engineering ceramics with a new-type ultrasonic honing machine was carried out. When the results are compared with those for common honing five characteristics are clear: (1) with the same cutting depth, the grooves scored in ultrasonic grinding are shallower; (2) the width at the bottom of the grooves is greater than that of common honing and close to the amplitude of the ultrasonic wave; (3) fracture and pits on the ultrasonically honed surface are shallower and peel off as layers, while those on the common honed surface exhibit chap abscission; (4) on the ultrasonically honed surface fracture mostly occurs on the boundary of the grooves and in even wide grooves fracture is much less extensive, whilst on the other hand, in common honing, at the bottom of the grooves a greater number of fractures were observed as well as on the boundary; (5) on the ground surface of ZrO2, for both methods, little chap cracking is visible, not as for a Si3N4 workpiece. Cracking under common honing is more than that of ultrasonic honing. At the fringe of the damage area for ultrasonic honing an extensive crack due to exceptional trans-crystalline rupture was found occasionally.