Ultrasonic vibration-assisted dry grinding is a sustainable hybrid manufacturing technology that decreases the negative environmental impact of coolant, reduces manufacturing costs, and improves surface integrity. The present investigation analyses the mechanisms associated with ultrasonic vibration-assisted dry grinding of AISI D2 tool steel with an alumina grinding wheel. It also compares the influence of traditional dry grinding and traditional wet grinding modes with the ultrasonic vibration-assisted dry grinding mode at different ultrasonic vibration amplitudes. Ultrasonic vibration was applied to the sample in the longitudinal feed direction. Further, kinematics of the abrasive grit path during the traditional grinding and ultrasonic vibration-assisted dry grinding is presented schematically. In this research, the impacts of ultrasonic vibration amplitude as well as the depth of cut on the process yields such as ground surface topography, grinding force, specific grinding energy, force ratio, surface finish, microstructure, and hardness were investigated experimentally. Experimental results revealed that the highest decline in tangential and normal grinding forces in ultrasonic vibration-assisted dry grinding at ultrasonic vibration amplitude 10 µm and the reduction in surface roughness parameter (R_a, R_q, and R_z) in ultrasonic vibration-assisted dry grinding was 43.23%, 42.59%, and 33.69%, respectively, in comparison to those in traditional dry grinding and 26.35%, 26.94%, and 27.48%, respectively, in comparison to those in traditional wet grinding. It was observed that ultrasonic vibration-assisted dry grinding is beneficial as the profile produced by ultrasonic vibration-assisted dry grinding has a comparatively flat tip, and profile points are shifted to the bottom of the mean line. This study is expected to assist ultrasonic vibration-assisted dry grinding of hard materials.

超声波振动辅助干磨是一种可持续的混合制造技术，可减少冷却液对环境的负面影响、降低制造成本并提高表面完整性。本研究分析了用氧化铝砂轮对 AISI D2 工具钢进行超声振动辅助干磨的相关机制。还比较了传统干磨和湿磨模式与超声振动辅助干磨模式在不同超声振幅下的影响。沿纵向进给方向对样品施加超声波振动。此外，还示意性地介绍了传统磨削和超声波振动辅助干磨期间磨粒路径的运动学。在这项研究中，实验研究了超声波振动幅度和切削深度对磨削表面形貌、磨削力、比磨削能、力比、表面光洁度、微观结构和硬度等加工产量的影响。实验结果表明，超声振动辅助干磨在超声振动振幅为 10 µm 时切向和法向磨削力下降最大，表面粗糙度参数降低（R _a、R _q和R _z ) 超声振动辅助干磨分别为43.23%、42.59%和33.69%，与传统干磨相比分别为26.35%、26.94%和27.48% ，与传统湿磨相比。观察到超声振动辅助干磨是有益的，因为超声振动辅助干磨产生的轮廓具有相对平坦的尖端，并且轮廓点移动到中线的底部。该研究有望辅助硬质材料的超声振动辅助干磨。