Design of a Compact 3-D Vibration-Assisted Turning Device With Large Amplitude and High Frequency for Diversified Microstructure Sculpturing

Abstract

The 3D vibration-assisted turning (VAT) has attracted increasing attention for its merits in microstructure sculpturing and ultra-precision machining. However, most current 3D VAT tools adopt complex structures and it is still difficult to implement high frequency and large amplitude simultaneously on a simple integrated tool. Here, a 3D VAT tool with high-frequency and large amplitude adjustment capability is proposed for the first time, which adopts a more stable and compact single sandwich piezoelectric transducer structure. High frequency and large amplitude adjustment capabilities improve the machining efficiency and the range of machinable microstructures. The structure of the tool is simplified by using the sandwich-type single transducer structure, which is convenient to reduce cost and improve machining stability. Surface microstructures with variable inclination angles and distribution ratios are firstly sculptured by the proposed 3D VAT tool, which provides a new idea for surface modification. In addition, surface microstructures with different depths and high-precision microgrooves are machined, and better machining results are obtained. The texture depth and machining efficiency of microstructure are increased with the increase of amplitude and frequency. Microgrooves with a surface roughness of Sa 29 nm, minimized burrs and defects, and a specific cutting force reduction of 54.8% are obtained.