Surface integrity in 3D ultrasonic vibration-assisted turning driven by two actuators

Abstract The surface integrity of machined parts is critical to their in-service function, longevity and overall performance. The integrity of the surface is dominantly affected by the chip formation process that can be significantly altered and controlled, among other methods, by ultrasonic vibration assistance. This work will explore the integrity of surfaces generated in three-dimensional ultrasonic vibration-assisted turning (3D-UVAT). The integrity of the obtained workpiece surfaces will be systematically explored in terms of surface roughness, the microstructure of the surface obtained by heat-assisted turning, surface hardness and wettability. A comparative assessment with other surface generation methods, i.e., common turning (CT), one-dimensional (UVAT) and two-dimensional elliptical ultrasonic vibration-assisted turning (EUAT) is also given. The results show that 3D-UVAT can reduce the depth of surface damage and enhance the hydrophobicity of the surface while reducing surface roughness.