Ultrasonic Vibration-Assisted Ball Burnishing Tool for a Lathe Characterized by Acoustic Emission and Vibratory Measurements.

This paper focuses on a resonant system used to induce a low-amplitude movement and ultrasonic frequency to complement a ball burnishing process on a lathe. The system was characterized through the combination of different techniques. A full vibratory characterization of this process was undertaken with the purpose of demonstrating that the mechanical system-composed of the tool and the machine-does not present resonance phenomena during the execution of the operation that could lead to eventual failure. This dynamic analysis validates the adequateness of the tool when attached to an NC lathe, which is important to guarantee its future implementation in actual manufacturing contexts. A further aim was to confirm that the system succeeds in transmitting an oscillating signal throughout the material lattice. To this end, different static and dynamic techniques that measure different vibration ranges-including impact tests, acoustic emission measurement, and vibration measurement-were combined. An operational deflection shape model was also constructed. Results demonstrate that the only high frequency appearing in the process originated in the tool. The process was not affected by the presence of vibration assistance, nor by the burnishing preload or feed levels. Furthermore, the frequency of the assisting ultrasonic vibration was characterized and no signal due to possible damage in the material of the specimens was detected. These results demonstrate the suitability of the new tool in the vibration-assisted ball burnishing process.

Monitoring of Processing Conditions of an Ultrasonic Vibration-Assisted Ball-Burnishing Process.

Although numerous references present the beneficial effects on surface integrity of ultrasonic vibration-assisted ball burnishing (UVABB), nothing has been reported about the dynamic behavior of the UVABB tool, workpiece, and machine triad during the process. In this paper, a dynamic monitorization through a set of 5 accelerometers is tested to analyze the interactions between the tool-workpiece-machine mechanical assembly. A UVABB tool attached to a milling machine and equipped with a piezoelectric stack that is able to assist the process with a 40-kHz vibration is tested on a milled C45 steel surface. First, the natural frequencies of the mechanical system are obtained through hammer impact tests. Then, the vibratory signals transmitted during the execution of the process are monitored and compared to those: two feed velocities and two burnishing preloads, all with and without vibration-assistance. Results show that the proposed accelerometer set is valid to assess the behavior of a UVABB process. The system's natural frequencies are not varied by vibration-assistance and are not excited when the piezoelectric is functioning. It is confirmed that UVABB is safe for the machine and the tool, and there is no unexpected excited frequencies due to the piezoelectric excitation.