Design and Evaluation of a Piezo-Driven Turning Tool for Machining Non-Circular Geometries

Abstract

Conventional turning processes are inherently limited to the generation of rotationally symmetric geometries due to the fixed kinematics between the cutting tool and the rotating workpiece. To overcome this limitation and enable the fabrication of non-circular profiles, a superimposed radial oscillation of the cutting tool can be introduced. This additional degree of freedom allows for the controlled deviation from circular paths, thereby enabling the machining of a broad spectrum of arbitrary geometries, constrained primarily by the actuator’s stroke amplitude. Precise synchronisation between the oscillatory motion of the tool and the angular position of the workpiece is essential to ensure contour fidelity and surface quality. In this context, a piezo-actuated turning tool was developed and experimentally evaluated. The system is capable of generating a sinusoidal radial displacement with a maximum amplitude of 85 µm. Experimental results demonstrate the tool’s ability to consistently and accurately reproduce non-circular profiles, confirming the feasibility and repeatability of piezo-assisted turning for advanced shape generation. The approach offers a promising solution for applications requiring high-precision non-rotationally symmetric components