Modeling of metallic surface topography modification by high-frequency vibration

High-frequency vibration is capable of modifying metallic surface topography significantly, while the underlying mechanisms are still unclear. In this study, the acoustic softening effect is considered to explain and model the effects of high-frequency normal vibration on surface topography. The surface asperities can be softened by the high-frequency vibration due to acoustic softening, leading to the enhancement of surface topography modification. A theoretical model for metallic surface topography modification by high-frequency vibration is proposed based on the acoustic plasticity. Numerical predictions of surface roughness evolution were conducted under various working conditions based on the model developed. It was found that the reduction of surface roughness (RSR) after vibration-assisted forming was affected by static stress, vibration amplitude, material properties and initial specimen surface roughness. The predictions using the developed model were compared with experimental data. Results showed that the predicted RSR agreed well with the experimental results, indicating that the analytical model is able to accurately capture surface topography evolution during vibration-assisted metal forming. This study provides a basis for understanding the underlying mechanisms of surface topography modification in vibration-assisted manufacturing.