Ultrasonic machining of titanium and its alloys: A review

Ultrasonic machining (USM) is a mechanical material removal process used to erode holes and cavities in hard or brittle work pieces by using shaped tools, high-frequency mechanical motion, and an abrasive slurry. Unlike other non-traditional processes such as laser beam, and electrical discharge machining, ultrasonic machining does not thermally damage the work piece or appear to introduce significant levels of residual stress, which is important for the survival of materials in service. The fundamental principles of stationary ultrasonic machining, the material removal mechanisms involved and the effect of operating parameters on material removal rate, tool wear rate, and work piece surface finish of titanium and its alloys are reviewed, for application in manufacturing industry.