Effect of surface/subsurface defects on the surface integrity of ceramic materials

Abstract Ceramic materials are widely used in engineering due to their superior mechanical properties, such as higher strength, thermal stability, and wear resistance. Achieving high surface integrity in ceramic components is still a challenge due to the damage induced during machining, particularly grinding. Thus, this review will provide a thorough overview of how surface roughness (SR) and subsurface damage (SSD) are formed by discussing the effects of various grinding parameters on surface integrity. The review highlights the transition from brittle fracture to ductile material removal mechanisms and the rising effect of critical cutting parameters, including undeformed chip thickness, grinding forces, and particular energy on defects on the surface. The influence on mechanical properties, fracture behavior, and change in micro-hardness caused by grinding induced by structural defects are also analyzed. In particular, various destructive and non-destructive damage assessment methods are evaluated against their efficiency in characterizing SSD. The intricate relationship between SR and SSD is critically assessed and emphasizing the need for more robust predictive models. Finally, the challenges in optimizing ceramic grinding processes are briefly explained, along with potential suggestions for future research directions regarding the machining efficiency and performance of advanced ceramics in industrial applications.