Influence of the Tool Geometry on the Surface Properties in Ultrasonic Vibration Superimposed Machining of Bronze

Ultrasonic vibration superimposed turning represents a highly efficient method for surface microstructuring, which enables a combination with finish machining. However, there are almost no industrial applications of this process due to the special kinematics. Furthermore, the effects of the varying cutting conditions combined with the tool geometry on the resulting surfaces and process stability are not yet fully understood. In experimental investigations, specimens consisting of bronze (CuSn7Pb15-C) are machined by ultrasonic vibration superimposed turning. The influence of the geometry of the MCD-tipped indexable inserts on the surface microstructure is analyzed. Indexable inserts with different rake angles (0°, −10°, and −20°) and artificially generated flank wear lands (widths 50 µm and 100 µm) are used. Moreover, the influences of the cutting speed (120 m/min, 480 m/min) and the feed (0.05 mm, 0.1 mm) are analyzed. While machining, the strain of the sonotrode is detected by an integrated fiber Bragg grating. Subsequent to machining, geometrical surface properties are determined by SEM and 3D surface analysis using focus variation. Furthermore, kinematic simulations are realized, enabling the comparison with the generated surfaces. Generally, there is a high concordance between the simulated and the generated surfaces. However, in particular when the tool flank face gets in contact with the specimen, deviations are visible, especially the formation of burr. Summarized, the research improves the understanding of the mechanisms in ultrasonic vibration superimposed turning and the formation of the surface microstructures.