The article presents an analysis of changes in the physical properties of the surface layer after the process of shaping difficult-to-cut materials. Obtaining the appropriate structure of the surface layer during machining is crucial for achieving the desired properties of the element – such as hardness, resistance to wear, corrosion, material fatigue or friction. The surface layer is not only a geometric surface – it is also a zone with modified physicochemical properties, the formation of which is controlled by physical phenomena occurring during cutting. Thermal phenomena occurring in the contact zone during its formation cause structural changes in the subsurface layer, hardening or softening it. Dynamic phenomena occurring during the machining process deteriorate the surface quality, cause waviness and microcracks. The paper presents the effect of surface shaping by vibration cutting and analyzes the physical aspects of surface morphology and evaluates the nature of the influence of process parameters – functional parameters of the surface layer. Experimental studies were carried out on four materials with different physical and structural properties: 1.4404 stainless steel, S235 structural steel, M1E electrolytic copper and EN AW-6060 aluminium alloy.

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