As a burgeoning surface finishing process, laser polishing (LP) introduces some undesired surface structures, limiting access to better laser-polished surfaces. Considering this, the paper proposes a novel hybrid processing method, ultrasonic vibration-assisted laser polishing (UVLP). Horizontal ultrasonic vibration, perpendicular to the laser scanning direction, is imposed on the workpiece, which promotes homogenized melt distribution in the melting pool, contributing to the polished surface flatness. Bulge, a typical surface structure formed in LP, serves as the verification vehicle for the effect of ultrasonic vibration here. In this investigation, comparative experiments were performed on 304 stainless steels to demonstrate the regulation phenomenon of ultrasonic vibration on the bulge formation. Subsequently, the corresponding numerical model was developed to explore the acting mechanisms of ultrasound from the thermal and hydrodynamic fields. The model also optimized the coupling method of volume expansion to better capture the change in melting pool volume during the polishing process, especially during the cooling phase. The results indicated that the forced melt oscillations are the dominant mechanism to uniformize the metallic materials distribution, regulating the bulge formed along the polished track. The degraded melt flow pattern, a simple harmonic oscillation, reached similar results. Furthermore, the developed model verified its effectiveness through surface flatness, melting pool dimensions, and microhardness.
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