Review of ultrasonic vibration-assisted machining in advanced materials

• Published in: International journal of machine tools & manufacture Vol. 156; p. 103594
• Main Authors: Yang, Zhichao, Zhu, Lida, Zhang, Guixiang, Ni, Chenbing, Lin, Bin
• Format: Journal Article
• Language: English
• Published: Elmsford Elsevier Ltd 01.09.2020; Elsevier BV
• Subjects: Advanced materials; Amplitudes; Computer architecture; Cutting characteristics; Cutting parameters; Machining; Ultrasonic transducers; Ultrasonic vibration; Ultrasonic vibration system; Ultrasonic vibration-assisted machining; Vibration analysis; Workpieces; Ultrasonic vibration system; Ultrasonic vibration-assisted machining; Cutting characteristics; Advanced materials
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/j.ijmachtools.2020.103594

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. [Display omitted] •The evolution of UVAM systems are comprehensively discussed in the paper.•Kinematics are analysed in view of cutting type, including Con-UVAM and R-UVAM.•Cutting characteristics (contact rate, force, surface integrity) are summarized.•Based on advantages and interdisciplinary, directions of development are concluded.