Ultrasonic-assisted machining processes: a review

Ultrasonic-assisted machining process is one of the most recently explored hybrid machining processes. In ultrasonic assisted machining process, an oscillating motion (of small amplitude and high frequency) is superimposed on the conventional machining operation. The assistance of ultrasonic vibrations in machining process improves the performance of the process by reducing cutting forces and enhancing surface quality. The effect of ultrasonic vibration has been found very beneficial in different conventional and non-conventional machining processes. This paper reviews the analytical and experimental studies in the area of ultrasonic-assisted turning, milling and drilling. Additionally, the effect of ultrasonic vibration on non-conventional machining processes is also reviewed. The paper also explains the effect of ultrasonic vibration on the cutting mechanics. The research gaps present in the ultrasonic-assisted machining process domain have also been highlighted in order to drive on the path of future research in this area.