In mechanical based machining processes, the surface topography is generated through series of hierarchical pattern. Plastic deformation as result of contact and kinematic of motion are two main factors which determine evolution of surface generation. To basically optimize the surface quality, accurate predictive model of surface generation and constraints are required. In the present work, analytical models of dimple formation and hierarchical surface generation in ultrasonic assisted ball burnishing process are proposed. Pile-up and sink-in as two phenomena of indentation during both of loading and unloading phases were taken into the developed models. Considering interaction of indentation profile and kinematic of motion, three-dimensional surface topography and surface roughness are also analytically predicted. A criterion for surface failure is defined to perform process without any erosion. Confirmation of results have been made by series of single trace and multi-traces burnishing experiments on AA6061-T6 and AISI 1045. The results of indention profile, surface topography, roughness and failure criterion which were derived from predictive models were completely consistent with confirmatory experiments.

在基于机械的加工过程中，表面形貌是通过一系列分层图案生成的。接触引起的塑性变形和运动的运动是决定表面生成演变的两个主要因素。为了从根本上优化表面质量，需要精确的表面生成预测模型和约束条件。在目前的工作中，提出了超声辅助球抛光过程中的凹坑形成和分层表面生成的分析模型。在装载和卸载阶段，堆积和下沉是两种压痕现象，被纳入开发的模型中。考虑到压痕轮廓和运动学的相互作用，还可以分析预测三维表面形貌和表面粗糙度。定义了表面破坏的标准以执行没有任何腐蚀的过程。通过在AA6061-T6和AISI 1045上进行的一系列单迹线和多迹线抛光实验对结果进行了确认。从预测模型得出的压痕轮廓，表面形貌，粗糙度和破坏准则的结果与验证性实验完全一致。 。