A hybrid machining technology with rotary ultrasonic roller burnishing process has been developed. There is no material removal when the machined surface is generated by the hybrid ultrasonic burnishing as comparing with other conventional cutting processes. The kinematic mechanism for plastic flow during surface generation in hybrid rotary ultrasonic burnishing Ti-6Al-4V with cylindrical roller tool was revealed in this paper. Firstly, the machining experiments were carried out for surface generation with hybrid rotary ultrasonic burnishing Ti-6Al-4V. Then, the experimental analysis was conducted and it showed that, there was little change in dimension of the rotary ultrasonic roller burnished workpiece compared to that of milled workpiece. Finally, a 3D finite element (FE) model was proposed to simulate the surface generation in hybrid rotary ultrasonic roller burnishing process. Three machining zones including pile-up deformation area, tensile deformation area, and compressive deformation area were selected for the analysis of the material plastic flow. It was found that the surface generated by rotary ultrasonic burnishing was mainly attributed to the plastic flow of material in these three deformation zones. The FE simulation results showed good agreements with the experimental ones. The proposed research results are helpful for the analysis and diagnosis of the surface generation in ultrasonic burnishing process.

已经开发了具有旋转超声辊抛光工艺的混合加工技术。与其他常规切割工艺相比，当通过混合超声打磨产生加工表面时，没有材料去除。揭示了用圆柱滚子工具在混合旋转超声抛光Ti-6Al-4V表面生成过程中塑性流动的运动机理。首先，进行了混合旋转超声抛光Ti-6Al-4V表面生成的机加工实验。然后，进行了实验分析，结果表明，与铣削工件相比，旋转超声辊抛光工件的尺寸变化很小。最后，提出了一种3D有限元模型来模拟混合旋转超声辊抛光过程中的表面生成。选择了三个加工区，分别是堆积变形区，拉伸变形区和压缩变形区，以分析材料的塑性流动。已经发现，通过旋转超声抛光产生的表面主要归因于这三个变形区域中材料的塑性流动。有限元仿真结果与实验结果吻合良好。所提出的研究结果有助于超声抛光过程中表面生成的分析和诊断。选择压缩变形区和压缩变形区，以分析材料的塑性流动。已经发现，通过旋转超声抛光产生的表面主要归因于这三个变形区域中材料的塑性流动。有限元仿真结果与实验结果吻合良好。所提出的研究结果有助于超声抛光过程中表面生成的分析和诊断。选择压缩变形区和压缩变形区，以分析材料的塑性流动。已经发现，通过旋转超声抛光产生的表面主要归因于这三个变形区域中材料的塑性流动。有限元仿真结果与实验结果吻合良好。所提出的研究结果有助于超声抛光过程中表面生成的分析和诊断。