Ultrasonic vibration-assisted milling technology for difficult-to-machine alloy materials in aerospace: current status and trends

Ultrasonic vibration-assisted milling (UVAM) technology introduces high-frequency mechanical vibration into conventional milling processes, effectively optimizing the distribution of milling forces, suppressing the rise in milling temperatures, extending tool life, and enhancing the quality of the machined surface. This approach offers a promising solution for machining difficult-to-machine alloys, such as titanium and superalloys, which are widely used in the aerospace industry. This paper systematically reviews the developmental history, fundamental principles, and classifications of UVAM. It analyzes the design methodologies of key components and thoroughly examines the technology’s performance and action mechanisms in the machining of challenging aerospace alloys. The analysis is conducted across multiple dimensions, including cutting forces, cutting temperatures, tool wear, and surface integrity. Furthermore, the paper explores emerging trends in UVAM, particularly in the areas of composite machining, green manufacturing, and the development of high-efficiency machining systems. The insights provided aim to support and advance related research and industrial applications.