Output Performance Optimization of Vibration-assisted Machining Devices Based on Assembly Preload Control

SONG Dunlan; DUAN Qing'an; LIN Jieqiong; WANG Jiwei; WANG Rongqi; HAO Zhaopeng; ZHOU Xiaoqin

doi:10.16490/j.cnki.issn.1001-3660.2026.16.012

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Surface Technology ›› 2026, Vol. 55 ›› Issue (16) : 156-166. DOI: 10.16490/j.cnki.issn.1001-3660.2026.16.012

Special Topic—Precision Machining of Difficult-to-Machine Materials

Output Performance Optimization of Vibration-assisted Machining Devices Based on Assembly Preload Control

SONG Dunlan¹, DUAN Qing'an¹, LIN Jieqiong¹, WANG Jiwei¹, WANG Rongqi^2,*, HAO Zhaopeng¹, ZHOU Xiaoqin²

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Abstract

In response to the output displacement fluctuation of vibration-assisted machining devices, the work aims to select a two-dimensional non-resonant direct-drive polishing tool system as the research object to improve the vibration output performance of the machining system by optimizing the assembly preload of piezoelectric ceramic actuators. Piezoelectric ceramic actuators are core excitation components for ultra-precision vibration-assisted machining due to their high positioning accuracy, fast dynamic response and compact structure. Nevertheless, mismatched assembly preload is a key factor causing unstable vibration output and displacement fluctuation of piezoelectric driving systems. Most current researches focus on structural optimization and driving signal modulation of vibration devices, while few studies quantitatively explore the coupling effect between assembly preload and output performance of two-dimensional non-resonant polishing systems. Therefore, this work optimizes the preload of piezoelectric actuators to eliminate displacement fluctuation and improve the overall vibration output stability of the polishing tool system.
The structural design of the vibration-assisted machining device is completed by combining the Matrix Compliance Model (MCM) and numerical simulation. The Matrix Compliance Model is adopted to analyze the static and dynamic mechanical characteristics of the flexible hinge and vibration transmission structure of the system, and numerical simulation is conducted to predict the stress distribution of piezoelectric stacks actuators and vibration output characteristics under different preload conditions. A dedicated performance test platform for the vibration-assisted device was built to test and evaluate the decoupling performance, natural frequency, step response, hysteresis characteristics, and maximum displacement of the prototype. In the experiment, the input driving voltage of the piezoelectric ceramic actuators was set in the range of 30 to 150 V, with the preload ranging from 60 to 180 N. The effect of external preload variation on the output displacement of the device under different input voltages was tested and analyzed. Finally, comparative polishing experiments on aluminum alloy workpieces were carried out with the optimal preload parameter, and the surface roughness parameter S_a was measured to verify the practical machining performance of the optimized system.
Experimental results reveal that the external preload applied on piezoelectric ceramic actuators has a regular regulating effect on the output displacement of the vibration device. Within the preload range of 60 to 180 N, the output displacement presents an overall trend of increasing first and then decreasing. The maximum output displacement is obtained at the preload of 90 N, and this optimal preload value is universally applicable within the driving voltage range of 30 to 150 V. The aluminum alloy surface is polished using a two-dimensional vibration-assisted machining device under the optimal assembly preload. After 35 min of polishing, the workpiece surface roughness S_a decreases from 0.262 μm to 0.098 μm.
Without adjusting the driving voltage, the output displacement of the vibration-assisted machining system can be effectively regulated via preload optimization. This research provides a novel method for active control and performance optimization of vibration-assisted machining systems. It effectively enhances the working adaptability of the machining system to diverse machining conditions, improves the operation reliability of piezoelectric vibration machining equipment, and provides technical support for the engineering application and industrial promotion of vibration-assisted ultra-precision machining technology.

Key words

vibration-assisted / preload / two-dimensional vibration / displacement / piezoelectric ceramic actuator / polishing

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SONG Dunlan, DUAN Qing'an, LIN Jieqiong, WANG Jiwei, WANG Rongqi, HAO Zhaopeng, ZHOU Xiaoqin. Output Performance Optimization of Vibration-assisted Machining Devices Based on Assembly Preload Control[J]. Surface Technology. 2026, 55(16): 156-166

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