Axial ultrasonic vibration end grinding (AUVEG) has been recognized as an efficient machining method for hard and brittle materials. In this paper, a theoretical model was proposed for predicting cutting force in AUVEG of BK7 optical glass with consideration of the nonuniform protrusion height of abrasive grits. Since the protrusion height of diamond grits was closely related to the cutting force, the modelling of the wheel end-face morphologies was performed to obtain the protrusion height information of diamond grits. Based on indention theory combined with energy perspective, a material removal rate model was proposed for establishing the cutting force model. Experiments were conducted to verify the validity of the proposed model, and the mean error between predicted and experimental force is 4.94%. The proposed model could be used in selecting process parameters for realizing high efficiency and precision AUVEG machining of BK7 optical glass.

轴向超声振动端面磨削（AUVEG）已被公认为是硬质和脆性材料的一种有效加工方法。本文提出了一种理论模型，该模型考虑了磨粒突出高度的不均匀性，预测了BK7光学玻璃在AUVEG中的切削力。由于金刚石砂粒的突出高度与切削力密切相关，因此对砂轮端面形貌进行建模以获得金刚石砂粒的突出高度信息。基于压痕理论和能量观，提出了一种材料去除率模型，用于建立切削力模型。通过实验验证了所提模型的有效性，预测力与实验力之间的平均误差为4.94％。