Development of a Novel 2-D Vibration-Assisted Compliant Cutting System for Surface Texturing

Abstract

This paper presents a novel two-dimensional vibration-assisted compliant cutting system (2-D VCCS) to be used on conventional machines for generating textured surfaces with uniform and accurate topography. The proposed system is specifically designed to be capable of delivering high-amplitude vibrations with decoupled guidance at the tool tip, while keeping high resistance to cutting forces during the texturing process. The matrix-based compliance modeling method is adopted for compliance and dynamic modeling of the 2-D VCCS. With optimized structural parameters, the model is validated by theoretical and finite element analysis. On-machine performance tests were conducted to identify the vibration amplitudes, stiffness, and frequency responses of the device. Finally, various complex textured surfaces were uniformly and accurately generated by the high-performance 2-D VCCS using a V-shaped diamond tool. The actually textured surfaces were evaluated and shown that they closely match the theoretically predicted surfaces based on the in-process monitored parameters, demonstrating the great potential of the 2-D VCCS to create functional surfaces for industrial products.