A comprehensive review on the evaluation and effectiveness of ultrasonic vibration-assisted devices in machining
Abstract
Ultrasonic vibration-assisted machining (UVAM) enhances the efficiency of material removal, particularly for difficult-to-machine materials, by superimposing high-frequency, low-amplitude vibrations onto the tool or workpiece. This technique introduces a microscopic, non-monotonic tool-workpiece interaction, significantly reducing burr formation, tool wear, and machining forces, while improving overall efficiency by minimizing the deformation zone during machining. UVAM has been effectively integrated into both conventional (e.g., turning, milling, drilling, and grinding) and non-conventional (e.g., laser, electrochemical, and electro-discharge) machining processes. Recent advancements in ultrasonic generators, transducers, and horn designs have driven rapid development of ultrasonic vibration-assisted devices (UVADs), leading to innovative designs. However, comprehensive investigations into UVADs remain limited. This article addresses this gap by providing an in-depth review of UVADs, focusing on their functional components, resonant and non-resonant designs (spanning 1D to 3D configurations). Furthermore, it examines UVAM modeling, finite element simulations, and the machining of materials such as metal alloys, composites, ceramics, and glass, offering valuable insights for advancing this promising technology.
Author
Nashwan Adnan OTHMAN
Publisher
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