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Open Access | Online First

Ultrasonic vibration-assisted micro-milling: A comprehensive review

Sami ULLAHa, Zhiqiang LIANGa,b,c( ), Yuchao DUa( ), Zhipeng SUa, Cheng GUOd, Zhen YINe, Haofei GUOa,b, Yoomi KIMa, Tianfeng ZHOUa,b, Xibin WANGa
School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China
Beijing Institute of Technology Chongqing Innovation Center, Chongqing 401120, China
Beijing Institute of Technology, Zhengzhou Academy of Intelligent Technology, Zhengzhou 450000, China
Shenzhen University, Shenzhen 518060, China
Suzhou University of Science and Technology, Suzhou 215009, China
Show Author Information

Abstract

Mechanical micro-milling has become a prominent micromachining technique in recent years, and it has advanced high machining efficiency and precision. The advantages of versatility, utility, cost-effectiveness, and efficiency make it suitable for varied industries such as biomedicine, electronics, aerospace, and aviation. However, Conventional Micro-Milling (CMM) faces difficulties, particularly in dealing with difficult-to-cut materials. To solve the above problems, Ultrasonic Vibration-Assisted Micro-Milling (UVAMM) is proposed, which can efficiently address the challenges of machining difficult-to-cut materials. UVAMM is able to inhibit chip formation and reduce the intense friction between the flank surface of the tool and the machined surface. What’s more, it can reduce cutting forces, cutting temperature, and residual stress on the workpiece surface. Finally, it leads to an enhancement in the finished surface quality of difficult-to-cut materials, maximizing the overall machining performance. This paper reviewed UVAMM processing, such as mathematical modeling, chip formation, burr formation, tool wear, cutting forces, cutting temperature, and surface morphology. Furthermore, the finite element simulation of UVAMM and the significance of Minimum Quantity Lubrication (MQL) in UVAMM are discussed. At the end, advantages of UVAMM for difficult-to-cut materials such as titanium alloys, steel alloys, nickel-based alloys, aluminum alloys, composites, brass, and optical glass are summarized.

Keywords

Surface roughnessMathematical modelingChip formationUltrasonic vibration-assisted micro-milling (UVAMM)Minimum quantity lubrication (MQL), Difficult-to-cut materials

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Journal of Advanced Manufacturing Science and Technology
Article number: 2025009
DOI: 10.51393/j.jamst.2025009
Cite this article:
ULLAH S, LIANG Z, DU Y, et al. Ultrasonic vibration-assisted micro-milling: A comprehensive review. Journal of Advanced Manufacturing Science and Technology, 2024, https://doi.org/10.51393/j.jamst.2025009

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Received: 22 January 2024
Revised: 15 March 2024
Accepted: 28 March 2024
Published: 03 September 2024
© 2025 JAMST

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