Design and experimental results of a tunable vibration turning device operating at ultrasonic frequencies

The development of a tunable ultrasonic vibration-assisted diamond-turning tool is described. The resonance operation method, which formerly served to achieve mechanical motion at ultrasonic frequencies, is now replaced by a newly developed pulse driving technique. The prototype tools allow for vibration frequencies from dc up to 40 kHz and vibration amplitudes from 0 to 10 μm. This paper reviews the design of the new tool system and summarizes the experimental results from diamond turning steel work materials. As in other studies on vibration-assisted machining, the results show that the surface turned with a vibrating tool contains scalloped geometric features superimposed on the tool marks left from conventional turning, resulting in a lower total surface roughness. Tool wear comparisons document advantages from the added vibration, and variations in the carbon content in the resulting chips were also examined.