Surface microstructuring by targeted burr formation using Ultrasonic Vibration Assisted Deformational Machining (UVADM) for improving polymer-metal bonding

Polymer-metal hybrids (PMH) are essential in lightweight industrial applications, particularly in the automotive and aerospace sectors. However, ensuring robust bonding between polymer and metal surfaces remains a significant challenge. Hence, surface microstructuring enables an improvement in adhesion due to mechanical interlocking. In this study, the microstructuring of the metallic surface by applying the Ultrasonic Vibration Assisted Deformational Machining (UVADM) process to enhance burr formation is analyzed. The research considers both the effect of a depth of cut ( a p ) of 25 µm, and the combined influence of a superimposed Ultrasonic Vibration (UV). A 3D finite element method (FEM) simulation using ABAQUS/Explicit software was conducted to design and analyze the process conditions, including the tool geometry. The main focus of the analysis is the evolution and characterization of the burr structure. In order to consider the plastic deformation of the material, the Johnson-Cook material model was employed. Besides the FEM simulation, experimental validation was carried out using specimens made of EN AW-6082 aluminum alloy. Surface topography including burr formation was characterized using optical methods. The results demonstrate that the interaction between a p and UV influences burr formation.