Ultrasonic vibration-assisted cutting of titanium alloys: A state-of-the-art review

The remarkable ability of titanium alloys to preserve their superior physical and chemical characteristics when subjected to extreme conditions significantly enhances their importance in the aerospace, military, and medical sectors. However, conventional machining of titanium alloys leads to elevated tool wear, development of surface defects, and reduced machining efficiency due to their low heat conductivity, and chemical affinity. These issues can be somewhat counteracted by integrating ultrasonic vibration in the conventional machining of titanium alloys and also enhance sustainability. This review article offers a holistic evaluation of the influence of ultrasonic vibration-assisted milling and turning on cutting forces, temperature, tool wear, and surface integrity, encompassing surface morphology, surface roughness, surface residual stress, surface hardness, and surface tribological properties during titanium alloys machining. Furthermore, it investigates the sustainability aspect that has not been previously examined. Studies on the performance of ultrasonic-assisted cutting revealed several advantages, including decreased cutting forces and cutting temperature, improved tool life, and a better-machined surface during machining. Consequently, the sustainability factor is improved due to minimized energy consumption and residual waste. In conclusion, the key challenges and future prospects in the ultrasonic-assisted cutting of titanium alloys are also discussed. This review article provides beneficial knowledge for manufacturers and researchers regarding ultrasonic vibration-assisted cutting of titanium alloy and will play an important role in achieving sustainability in the industry.