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

Abstract

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.

Analysis of Ultrasonic Vibration-Assisted Ball Burnishing Process on the Tribological Behavior of AISI 316L Cylindrical Specimens

“…The vibration-assisted ball burnishing system used for this investigation is composed of the burnishing tool (the union of a base armor, a pre-load unit force based on a calibrated spring, one ultrasonic actuation unit built by a resonant ceramic piezoelectric excited to 40 kHz of frequency and an operational head formed by one 10 mm diameter 100Cr6 chromium steel ball at the top) and an external 40 kHz wave generator both plugged by a UFH connector, characterized by Fernández-Osete et al [ 25 ]. The amplitude of vibration obtained at the top of the tool by the resonance of the system is about 8 μm.…”

Current Trends in the Development of Automation Systems in Mechanical Engineering

“…It should be noted that the priority direction of improving the competitiveness of machines is to improve their quality due to the developed standard layout schemes of the spindle assembly, as well as accuracy and strength indicators, at least ± 1,5 %, which fully meets the requirements of GOST and technical conditions of production operation. Research teams [32,33] describe a number of problems that focus mainly on the stiffness indicators of machine tools of any type [34]. At the same time, the permissible limits of the main parameters put forward by the standards for the operation of lathes are not taken into account, as well as external conditions that may affect the operation of the lathe are not taken into account.…”

2D FEM Investigation of Residual Stress in Diamond Burnishing

“…Jerez-Mesa et al [12] investigated the ultrasonic vibration-assisted ball burnishing process and how to develop a vibration-free version of it, as well as the consequences for the topology and subsurface microstructure of the concrete workpiece. Fernández-Osete et al [13] studied the acoustic emission and vibration measurements of an ultrasonic vibration-assisted ball burnishing tool mounted on a lathe. The authors focus on a resonating system that includes both low-amplitude motion and an ultrasonic component to complete the ball burnishing process on a lathe.…”