A Compact Ultrasonic Burnishing System for High Precision Planar Burnishing: Design and Performance Evaluation

A novel ultrasonic burnishing (UB) system with a flat tool using a piezoelectric longitudinal transducer (PLT) is proposed. High-precision no-feeding mark planar burnishing can be achieved by the compact system with a size of only 280 × 224 × 558 mm without the need for machine tools. Above all, the structure of the burnishing system is presented and the operation principle is analyzed in detail. A resonant frequency design method of the PLT with a tool head is discussed. Based on this, the PLT achieves the expected resonant frequency precisely. Subsequently, the test system for the PLT is built and the resonant frequency and vibration amplitude are tested, which are in good agreement with the simulation results. Ultimately, the UB experiments are carried out and the results indicate that the surface roughness of the workpiece is reduced from Ra 1.6
μ
m to Ra 0.182
μ
m, which is reduced by 88.31%. Furthermore, the surface topography shows that the surface without the feeding mark is generated, which is beneficial to improve the burnishing accuracy and expand the application in ultra-precision processing.