Theoretical and experimental study of 3D ultrasonic vibration-assisted turning driven by two actuators

Ultrasonic vibration-assisted turning techniques can be used to reduce the roughness of the output surface and also to obtain special texture structures. This paper introduced an adjustable 3D ultrasonic vibration-assisted turning device, which has two operating modes, one for reducing the roughness of the output surface, and the other for constructing special textures with hydrophobic properties. Theoretical calculations, geometric modeling, finite element simulation and harmonic response analysis were used to guide the design process, and finally experimental verification was performed. The amplitude calibration results show that a 3D spatial elliptical vibration pattern of the turning tool can be realized. The experimental results indicate that a small cutting speed and a low feed rate help to reduce the roughness of the finished surface, while a large cutting speed and a large feed rate are good for increasing the contact angle of the output surface.