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<p>Ultrasonic vibration-assisted machining enhances material removal efficiency by applying micro-scale, high-frequency, low-amplitude vibrations to the tool or workpiece. This technique creates non-monotonic tool-workpiece interactions, reducing machining forces, tool wear, and surface deformation while improving chip separation and burr suppression. Ultrasonic vibration-assisted machining has been successfully applied in operations like turning, milling, drilling, and grinding, particularly for difficult-to-machine materials. Recent advancements in ultrasonic generators, transducers, and horn structures have further accelerated its development. This article provides an in-depth review of Ultrasonic vibration-assisted machining principles (1D to 3D) and its applications for challenging materials, including metal alloys (titanium, nickel-based, steel, tungsten), composites (metal matrix, CFRP), ceramics, and glass. Additionally, the sustainability aspects of ultrasonic machining are discussed.</p> Graphic abstract <p></p>

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A review on recent advancements in ultrasonic vibration-assisted machining of difficult-to-machine materials

  • 期刊论文

  • 发表日期：

    2025年5月29日

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  • M. Arslan Khan,
  • Ali B. M. Ali,
  • Sami Ullah,
  • Mubashir Umeed,
  • M. Ijaz Khan,
  • Asad Muhammad Khaqan,
  • Nashwan Adnan Othman,
  • Dilsora Abduvalieva

摘要

Ultrasonic vibration-assisted machining enhances material removal efficiency by applying micro-scale, high-frequency, low-amplitude vibrations to the tool or workpiece. This technique creates non-monotonic tool-workpiece interactions, reducing machining forces, tool wear, and surface deformation while improving chip separation and burr suppression. Ultrasonic vibration-assisted machining has been successfully applied in operations like turning, milling, drilling, and grinding, particularly for difficult-to-machine materials. Recent advancements in ultrasonic generators, transducers, and horn structures have further accelerated its development. This article provides an in-depth review of Ultrasonic vibration-assisted machining principles (1D to 3D) and its applications for challenging materials, including metal alloys (titanium, nickel-based, steel, tungsten), composites (metal matrix, CFRP), ceramics, and glass. Additionally, the sustainability aspects of ultrasonic machining are discussed.

Graphic abstract