Compared to conventional machining (CM), ultrasonic vibration-assisted machining (UVAM) with high-frequency and small-amplitude has exhibited good cutting performances for advanced materials. In recent years, advances in ultrasonic generator, ultrasonic transducer, and horn structures have led to the rapid progress in the development of UVAM. Following this trend, numerous new design requirements and theoretical concepts have been proposed and studied successively, however, very few studies have been conducted from a comprehensive perspective. To address this gap in the literature and understanding the development trend of UVAM, a critical overview of UVAM is presented in this study, covering different vibration-assisted machining styles, device architectures, and theoretical analysis. This overview covers the evolution of typical hardware systems used to achieve vibratory motions from the one-dimensional UVAM to three-dimensional UVAM, the discussion of cutting characteristics with periodic separation between the tools and workpiece and the analysis of processing properties. Challenges for UVAM include ultrasonic vibration systems with high power, large amplitude, and high efficiency, as well as theoretical research on the dynamics and cutting characteristics of UVAM. Consequently, based on the current limitations and challenges, device improvement and theoretical breakthrough play a significant role in future research on UVAM.

Review of ultrasonic vibration-assisted machining in advanced materials

Minimum quantity lubrication machining of aeronautical materials using carbon group nanolubricant: From mechanisms to application

Products made of titanium and its alloys are widely used in modern areas like the mechanical engineering, instrument making, aerospace and medical sector. High strength and low thermal conductivity are the causes of difficulties with the machinability of these alloys. It is important to find ways to increase machinability by cutting titanium alloys. One way to implement this is to apply various methods of cooling on workpieces of titanium alloys and on cutting tools during machining. In this review article, an extensive analysis of the literature on such cooling techniques as dry, conventional cooling system, minimum quantity of lubricant (MQL), minimum quantity cooling lubrication (MQCL), cryogenic lubrication, and high-pressure cooling (HPC) is performed. The following groups of Ti alloys are considered: high-strength structural and high-temperature Ti alloys, intermetallic compounds, pure titanium, as well as composites CFRPs/Ti alloys. For the processes of turning, milling, drilling, and grinding, etc. it is shown how the type of cooling affects the surface integrity include surface roughness, tool wear, tool life, temperature, cutting forces, environmental aspects, etc. The main advantages, disadvantages and prospects of different cooling methods are also shown. The problems and future trends of these methods for the machining of Ti and its alloys are indicated.

Improvement of machinability of Ti and its alloys using cooling-lubrication techniques: a review and future prospect

Lubrication-enhanced mechanisms of titanium alloy grinding using lecithin biolubricant

On a computer you can delete directories with reckless abandon. Whole tree structures of folders can be obliterated with just one multiple selection and a control key combination. It's great fun but maybe a bit too powerful at times. Anyway, I have just been doing the real world equivalent; burning real world direc-tories/folders on a real world bonfire, also great fun even if it lacks an undo function. This may seem rather wasteful but there is a reason. I'll start, though, with the filing cabinets I bought 15 years ago from an Ameri-can town planner. They were 50's styled, rounded corners, Cole Steel, just the right height for a desk-top placed on top of them; absolutely perfect. There was only one slight, minor, tiny drawback; they were for paper of the American 'letter' size and here in the UK we use 'A4' which is a slight, minor, tiny bit bigger. I tried A4 paper in the drawers and they fit... but only just. So I bought the cabinets. It was like when you find a great pair of secondhand shoes that are just that incy-wincy bit too small; you kid yourself they fit and then spend the next month walking around with curled up toes and blisters. Well, I kidded myself about the Cole Steel cabinets and spent the next month with A4 paper that was always slightly crumpled at the edges. Eventually I could stand it no more and while living in Holland I switched to European sizes. Faced with a choice of A4 or the larger Folio I chose Folio having had more than enough of curled edges. I built up a large collection of information (partly through a policy of never throwing anything out!) and when I returned to the UK I took all the files with me. On purchasing a filing cabinet to hold all the files I discovered that the UK, like Holland, has two sizes. Unfortunately, they are not the same two sizes; we have the choice between A4 or something called Foolscap. (I'm still unsure what a cap for a fool has got to do with paper, but there you go!). So I paid my money, got my cabinets, re-filed everything in foolscap-sized files and burned the Dutch folders on the bonfire. Such international compatibility horror stories are not new. It's not just a paper thing, it covers many other facets of life …

International standards

The original version of this article contained a mistake. Figure7 in the original article is incorrect.

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Correction to: Development of a tool-workpiece thermocouple system for comparative study of the cutting temperature when high-speed ultrasonic vibration cutting Ti-6Al-4V alloys with and without cutting fluids

The successful implementation of high-speed ultrasonic vibration cutting (HUVC) to improve the machinability of the Inconel 718 alloy has been reported in literature. However, the influence of HUVC on the surface integrity of the Inconel 718 alloy has not been investigated. In this context, this study is the first attempt to integrate cutting operations and mechanical surface treatment into one step via HUVC. To this end, an experiment was performed to compare the surface integrity of conventional cutting (CC) and HUVC using coated carbide tools at high cutting speeds (80–240 m/min). The experiment revealed that HUVC led to a lower surface roughness, regular surface micro-texture, deeper subsurface deformation zone (up to 104.47 μm), higher surface micro-hardness rate (by up to ~50%), and higher surface compressive residual stress (−1772 to −2323 MPa) compared to CC. In some occasions, a single HUVC step can be used to satisfy requirements originally addressed over two distinct steps (cutting operation and mechanical surface treatment) by improving surface integrity.

Integration of finishing and surface treatment of Inconel 718 alloy using high-speed ultrasonic vibration cutting

Influences of machining parameters on tool performance when high-speed ultrasonic vibration cutting titanium alloys

A transient cutting temperature prediction model for high-speed ultrasonic vibration turning

A high-speed ultrasonic vibration cutting (HUVC) method has been proposed for the precision machining of Ti and Ni alloys with high efficiency and fine surface quality in recent years. During the HUVC, the tool life can be enhanced significantly at a relatively high cutting speed. The effective cooling due to the tool-workpiece separation resulting from the ultrasonic vibration is regarded as the primary reason for these advantages. In order to figure out the influences of effective cooling and ultrasonic vibration for further understanding of the mechanism of HUVC and guidance of practical engineering, a quantitative relationship between the tool life and cutting conditions (including cutting, ultrasonic and cooling parameters) needs to be built. Therefore, in this paper, a tool life prediction model based on Taylor’s equation was established. Both the cooling contribution during the separation interval and tool impact resulting from the ultrasonic vibration were added to be considered. Then, experiments were conducted and the results showed that the separation effect with effective cooling was the main reason for the considerable benefits of HUVC. Although the impact was inevitable, high-speed, stable cutting regions of Ti and Ni alloys could still increase to 200–450 and 80–300 m/min, respectively. The prediction model could be used to optimize the cutting parameters and monitor the machining process according to the actual machining requirements.

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Zhenlong Peng

Papers

Correction to: Development of a tool-workpiece thermocouple system for comparative study of the cutting temperature when high-speed ultrasonic vibration cutting Ti-6Al-4V alloys with and without cutting fluids

Integration of finishing and surface treatment of Inconel 718 alloy using high-speed ultrasonic vibration cutting

Influences of machining parameters on tool performance when high-speed ultrasonic vibration cutting titanium alloys

A transient cutting temperature prediction model for high-speed ultrasonic vibration turning

A Tool Life Prediction Model Based on Taylor’s Equation for High-Speed Ultrasonic Vibration Cutting Ti and Ni Alloys