Experimental and modeling study of surface topography generation considering tool-workpiece vibration in high-precision turning

High-precision turning (HPT) is a main processing method for manufacturing rotary high-precision components, especially for metallic parts. However, the generated vibration between tool tip and workpiece during turning may seriously deteriorate the surface integrity. Therefore, exploring the effect of vibration on turning surface morphology and quality of copper parts using 3D surface topography regeneration model is crucial for predicting HPT performance. This developed model can update the machined surface topology in real time. In this study, the effects of tool arc radius, feed rate, radial vibration, axial vibration and tangential vibration on the surface topography and surface roughness were explored. The results show that the effect of radial vibration on surface topography is greater than that of axial vibration and tangential vibration. The radial vibration frequency is also critical. When vibration frequency changes, the surface topography profile presents three different types: the standard sinusoidal curve, the sinusoidal curve whose low-frequency signal envelopes high-frequency signal, and the oscillation curve whose low-frequency signal superimposes high-frequency signal. In addition, HPT experiment was carried out to validate the developed model. The surface roughness obtained in the experiment was Ra=53 nm, while the roughness obtained by the simulation was Ra = 46 nm, achieving a prediction accuracy of 86.7 %.