Review on the application of ultrasonic vibration-assisted turning in enhancing machinability of Ti-6Al-4V alloy

Ti-6Al-4V alloy is an α+β titanium alloy that is widely used in aerospace, marine, automobile, architectural, power/energy sectors, and various medical equipment industries due to its exceptional properties, including low density, high fracture toughness, excellent creep and corrosion resistance, a high strength-to-weight ratio, and superior biocompatibility. However, due to some other properties, such as poor thermal conductivity, high heat stress, low elastic modulus, high chemical reactivity, and significant work hardening, it is classified as a difficult-to-cut material. These kinds of materials face difficulties in cutting, such as heat concentration in the cutting zone, high cutting forces, and tool wear acceleration, which results in poor surface finish quality. Therefore, an ultrasonic vibration-assisted turning (UVAT) method has been proposed, which proved to be an efficient method to overcome these difficulties during Ti-6Al-4V titanium alloy cutting. This review article presents the application of the Ti-6Al-4V alloy, the principle of UVAT, and the impact of UVAT on various factors, including chip formation, tool wear, cutting forces, cutting temperature, surface morphology, and roughness. In addition, the significance of minimum quantity lubrication (MQL) in UVAT of Ti-6Al-4V alloy and the finite element analysis (FEA) of UVAT of Ti-6Al-4V alloy are summarized. Expected outcomes include a deeper understanding of the improvements in surface quality, reduction in cutting forces, and enhanced tool life through the UVAT process. The findings aim to guide future research and provide practical insights for manufacturers looking to optimize machining of Ti-6Al-4V alloys for better performance and sustainability in manufacturing processes.