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Ultrasonic vibration-assisted micro-milling: A comprehensive review

January 2024
Journal of Advanced Manufacturing Science and Technology 5(2):2025009

DOI:10.51393/j.jamst.2025009

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Sami Ullah

Beijing Institute of Technology

Zhiqiang Liang

Beijing Institute of Technology

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Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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Advanced Manufacturing Science and Technology

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2025009-1

Journal of

Advanced Manufacturing

Science and Technology

《先进制造科学与技术》国际期刊

ISSN: 2709-2135

eISSN: 3008-0991

Scopus数据库收录 CiteScore 2023=4.1

大连理工大学 & 航空发动机先进制造技术教育部工程研究中心主办

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

aSchool of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China

bBeijing Institute of Technology Chongqing Innovation Center, Chongqing 401120, China

cBeijing Institute of Technology, Zhengzhou Academy of Intelligent Technology, Zhengzhou 450000, China

dShenzhen University, Shenzhen 518060, China

eSuzhou University of Science and Technology, Suzhou 215009, China

Received 22 January 2024; revised 15 March 2024; accepted 28 March 2024; Available online 3 September 2024

Abstract: Mechanical micro-milling has become a prominent micromachining technique in recent years, and it has advanced high machin‐

ing 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 tempera‐

ture, and residual stress on the workpiece surface. Finally, it leads to an enhancement in the finished surface quality of difficult-to-cut materi‐

als, maximizing the overall machining performance. This paper reviewed UVAMM processing, such as mathematical modeling, chip forma‐

tion, 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: Ultrasonic vibration-assisted micro-milling (UVAMM); Mathematical modeling; Chip formation; Surface roughness; Minimum

quantity lubrication (MQL), Difficult-to-cut materials

2025009

1. Introduction

The need for precision and micromachining technologies, which

are used to create mechanical components with characteristics that

are measured in microns, has been rapidly increasing in biomedi‐

cine, electronics, aerospace, and aviation industries 1-8, as presented

in Fig. 1. With the increasing demands of these industries, conven‐

tional micromachining techniques cannot meet the requirements

since they have reached their upper limit 9-11. To address this defi‐

ciency, it is necessary to investigate and implement novel microma‐

chining techniques capable of efficiently fabricating complex me‐

chanical components at the micron scale 12. Specially, it involves la‐

ser microfabrication 13-15 , lithography, electroplating and shaping

(LIGA) 16,17 , deep UV lithography 18,1 9, electrical discharge machin‐

ing 20-22, deep reactive ion etching 23,24, and mechanical microma‐

chining techniques 25-29. These methods have very high precision

and minor tolerances, but there are still many problems, such as

working time, cost, material compatibility, thermal deformation,

and preprocessing. In order to achieve greater productivity, cost-ef‐

fectiveness, and processing flexibility, we require novel surface pro‐

cessing technologies that use conventional cutting techniques 12.

Previous studies show that ultrasonic vibration-assisted cutting

(UVAC) proved to be an innovative technique to promote process‐

ing performance and product quality 30-3 2. UVAC is a cutting meth‐

od that improves cutting efficiency by applying vibration to a tool

or workpiece 33. The main idea of UVAC is to separate the tool and

workpiece repeatedly. UVAC was first used in the late 1950s 34.

Then, UVAC is now widely used in the precision manufacturing of

various materials. UVAC produces thinner chips and reduces cut‐

ting forces, resulting in higher machining efficiency, longer tool

life, better surface quality, and a more precise shape while reducing

burr formation 30,34-37.

Ultrasonic vibration-assisted micro-milling (UVAMM) is an ad‐

vanced machining method that involves introducing vibration into

———————————

—

* Corresponding author. E-mail address: liangzhiqiang@bit.edu.cn(Zhiq‐

iang LIANG), dycfelix@163.com(Yuchao DU)

Peer review under responsibility of Editorial Committee of JAMST

DOI: 10.51393/j.jamst.2025009

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

2025009-2

the machining process 33. According to previous researchers, it can

be classified into various types according to the vibration direction,

which can be either one-dimensional 38, two-dimensional 39 , or

three-dimensional 40. Ultrasonic vibration can be applied to either

the cutting tool or the plane of the workpiece in UVAMM 38. It

plays an important role in satisfying the increasing need for tiny

components with complex 3D geometries. The size effect has an

impact on the blunt radius of cutting tools, and it is no longer ac‐

ceptable to ignore it, especially when working with difficult-to-cut

materials 41. UVAMM is considered a highly effective method for

machining difficult-to-cut materials. So, it leads to a distinctive cut‐

ting action in comparison to equivalent machining 42 . What’s more,

the latest research has shown significant interest in UVAMM for

difficult-to-cut materials, which is able to solve the challenges re‐

sulting from conventional micro-milling (CMM). So, the research‐

ers have extensively studied UVAMM, investigating its application

in difficult-to-cut materials 43. Based on these benefits of UVAMM,

many researches concerning further machining mechanism were

conducted. For example, relationship between the ratio of mini‐

mum chip thickness to cutting-edge radius and many parameters,

such as the plowing effect, effective rake angle, and specific cutting

energy of the machined surface, has been noted. Furthermore, it

can directly impact the cutting performance and reduce the impact

of both the size effect and the plowing effect 44-46. Consequently, it

can enhance cutting efficiency by avoiding these negative impacts.

UVAMM has revealed significant developments in recent years

and offered a lot of benefits compared to CMM. Many studies have

investigated the impact of various processing parameters, such as

frequency, amplitude, workpiece material, microstructure, and ef‐

fective tool trajectories, on output parameters such as chip forma‐

tions, burr formation, tool wear, milling forces, milling tempera‐

ture, and surface roughness. For example, UVAMM has enhanced

efficiency in chip breaking through the application of ultrasonic vi‐

brations 47, resulting in a reduction in unwanted burr formation,

which is a common issue in CMM 48,49. It can result in producing

smoother and more precise machined surfaces. In addition,

UVAMM helps reduce tool wear while improving their service life

and cost-effectiveness 50. UVAMM outperforms CMM by employ‐

ing ultrasonic vibrations to help with the cutting process, resulting

in reduced cutting forces and the generation of heat. This method

improves material removal accuracy while reducing cutting forces

51,52, reducing cutting temperature 53, and leading to the improve‐

ment of precision and operational effectiveness. As a result, it pro‐

duced a smoother and more precise machined surface by reducing

the surface roughness in comparison to CMM 36,54.

The primary objective of this article is to provide an in-depth re‐

view of the most recent developments in UVAMM. It encompasses

various aspects such as UVAMM processing, which include mathe‐

matical modeling, chip formation, burr formation, tool wear, cut‐

ting forces, cutting temperature, and surface morphology; the finite

element simulation of UVAMM; the significance of MQL in

UVAMM; and applications of UVAMM for difficult-to-cut materi‐

als such as titanium alloys, steel alloys, nickel-based alloys, alumi‐

num alloys, composites, brass, and optical glass. The main purpose

is to integrate and explain the most recent knowledge and develop‐

ments in the field of UVAMM.

2.Ultrasonic vibration-assisted micro-milling

(UVAMM) processing

In UVAMM, high-frequency and low-amplitude vibration is ap‐

plied to the microscopic tool or workpiece to improve the efficien‐

cy of material removal, particularly for difficult-to-cut materials.

Compared with CMM, UVAMM even removes dislocations within

the crystal structure of the material that hinder the material's ability

to deform and make it harder. By reducing dislocations, the materi‐

al strength reduces and it becomes easier to cut, which helps to

break the chips more effectively, and ultimately, the friction and

heat generation between the cutting tool and the workpiece reduce.

In addition, vibration helps to remove chips from the milling zone

and prevent their re-engagement, which results in a reduction in

cutting forces, tool wear, and burr formation. As a result, the mate‐

rial undergoes a change in its physical properties and becomes soft‐

er or more pliable, allowing for smoother cutting and improved

surface finishes 55,56. However, the significance of thermal soften‐

ing compared to dislocation activation depends on the material

properties and machining parameters. UVAMM has emerged as a

potential response to the increasing difficulties in achieving higher

levels of precision and efficiency in production 57,58. Fig. 2 illus‐

trates different types of ultrasonic vibration-assisted milling

(UVAM) and categorizes them based on distinct tool tip path char‐

acteristics. Every type presents distinct benefits and is appropriate

for specific applications. Fig. 3 illustrates the percentage of studies

conducted in UVAMM processing that involve different output pa‐

rameters such as mathematical modeling, chip formation, burr for‐

Fig. 1 High precision micro milling structures (a) Electric vacuum amplifier 1(b) Micro-nozzles 2(c, d) Micro-machining components 3,4

(e) Micro-pin fins 5(f) Micro-channels 6(g, h) Micro-molds 7,8

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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mation, tool wear, cutting forces, cutting temperature, and surface

morphology.

2.1. Mathematical modeling of machining mechanism

The introduction of mathematical modeling in UVAMM offers

an organized approach to understand and improve the complex rela‐

tionships inside machining processes. The researchers aim to repre‐

sent the changing relationships between the different components

which influence UVAMM by employing mathematical equations.

This model can accurately assess the quantitative effects of ultra‐

sonic vibration on variables such as tool wear, milling force, and

surface quality 50,59,60. By employing mathematical models, research‐

ers can simulate and predict the complex movement of tools and

workpieces in the context of UVAMM 50,61. This enables them to

gain significant insights into optimizing the process, developing

tools, and enhancing overall performance in micro milling applica‐

tions. Table 1 provides an overview of the mathematical models

that have been developed using UVAMM.

2.2. Chip formation

Undeformed chip thickness is an important consideration in mi‐

cro-milling as it directly impacts chip formation, milling forces,

surface roughness, and tool wear. The significance of it resides in

its size, which is comparable to the radius of the cutting edge, lead‐

ing to possible scale effects. Consequently, numerous models have

been suggested for predicting the undeformed chip thickness in mi‐

cro-milling 6 3. However, the chip thickness produced in UVAMM

different from that in CMM because of the alteration in the tool

tip's relative path. The difference becomes more evident when the

design of the object that is being worked on develops complex and

experiences vibration 49.

In the field of micromachining, the impact of the cutting-edge ra‐

dius becomes noticeable when the thickness of the chip that has not

been deformed falls below a specific value known as the minimum

chip thickness, as presented in Fig. 4. The minimum chip thickness

has a major impact on several machining factors, including as mill‐

ing forces, tool wear, surface integrity, and process stability. Hence,

it is essential to determine the minimum chip thickness in order to

choose suitable machining conditions 64.

The microchip removal method illustrated in Fig. 5 demon‐

strates the essential importance of the minimum chip thickness.

When the undeformed chip thickness (h) is below the minimum

chip thickness (hmin)65, as illustrated in Fig. 5(a), the cutting tool

only applies force to the material without generating chips. This

results in elastic deformation and affects the surface quality. As h

reaches hmin in Fig. 5(b), chips start to form due to the shearing ac‐

tivity in the main shear zone, and the impact of ploughing be‐

comes noticeable. When h is more than hmin (as seen in Fig. 5(c)),

there is a continual generation of chips due to stable plastic defor‐

mation in the shear zone, even though there is some elastic materi‐

al recovery. Usually, the initial thickness of the chip (h) is greater

than the amount of material being removed, comparable to the way

material is removed in quasi-homogeneous materials 63 . Son et al. 66

presented an advanced approach for ultra-precision cutting. The

purpose of the model is to calculate the smallest possible thickness

of an unaltered metal chip, known as the minimum chip thick‐

ness (hmin).

Fig. 3 Development trend of the UVAMM studies.

Fig. 2 Types of ultrasonic vibrations in milling process.62

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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hmin =re

( )

1−cos

( )

4−β

(1)

In Eq. (1), hmin is minimum undeformed chip thickness, reis radi‐

us of the blunt circle of the cutting edge, and βis the friction angle

between the tool and the workpiece material.

On the other hand, a phase difference between two adjacent tool

cutting trajectories during UVAMM machining will cause a change

in the chip thickness. Some sections of the chip observe a relative

increase in thickness, while other sections maintain a relative thin‐

Fig. 5 Illustration of microchip removal mechanism.80 ,81

Fig. 4 Effect of micro milling tool cutting edge radius on chip morphology.41

Table 1 Summary of mathematical modeling in UVAMM.

No.

Authors

Ding et al. 49,59

Lian et al. 37

Ibrahim et al. 3 8

Ibrahim et al. 7 0

Chen et al. 71

Zheng et al. 72

Zhang et al. 73

Mokhtari et al. 39

Tan et al. 54

He et al. 74

Sobamowo et al. 75

Zheng et al. 50

Shang et al. 61

Huan et al. 53

Yuan et al. 76

Shang et al. 77

Yuan et al. 78

Yan et al. 40

Zhang et al. 48

Su et al. 79

Year

2010-2011

2013

2014

2015

2018

2019

2020

2022

2023

Vibration type

1D, 2D

Mathematical models

Machining process dynamics, milling force model, tool kinematics

trajectory, chip thickness model

Tool kinematics trajectory

Cutting tolerance, surface finish, tool wear

Kinematic motion trajectory of tool

Dynamic analysis of vibrator, tool kinematic trajectory, surface tex‐

ture generation

Surface generation modeling

Cutting force prediction model, undeformed chip thickness model

UVAMM system model, motion model

Principle of UVAMM

Mechanism of UEVAMM

Cutting force model, dynamic behavior, chip thickness

Tool kinematic trajectory, tool-workpiece separation

Tool kinematic trajectory

Cutting temperature model

Tool kinematic trajectory

Surface formation mechanism

Tool kinematic trajectory

Tool kinematic trajectory, surface topography model

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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ness. Therefore, these elements have a natural tendency to break.

The chips generated under these circumstances exhibit significant

differences in terms of thickness and length when compared to

those produced in a CMM. The phenomenon demonstrates the

unique thickening cutting properties that are specific to the

UVAMM process. According to Fig. 6(a), chip production in

UVAMM mostly involves the extrusion process occurring between

the cutting edge and the workpiece. Moreover, chip creation in

UVAMM involves a combination of expansion and edge impact.

Chip deformation is caused by the application of ultrasonic stress.

It is important to mention that in UVAMM, although the unde‐

formed cutting thickness (h) being smaller than the minimum cut‐

ting thickness (hmin) needed for conventional chip production, ultra‐

sonic vibration can increase the cutting thickness over hmin , result‐

ing in periodic modifications in the cutting shape. Fig. 6(b) demon‐

strates the effectiveness of ultrasonic vibration in continuously

maintaining the cutting thickness at a steady value 48,7 8. In addition,

once the cutting-edge radius and material are determined, the mini‐

mum cutting thickness in UVAMM becomes a constant value. For

a given cutting edge radius and material, such as Inconel718, the

minimum cutting thickness remains constant, irrespective of other

variables. Eq. (2) is a mathematical formula for determining the

minimum chip thickness for cutting Inconel718 82.

hmin = 0.25 (2)

where, rerepresent the cutting-edge radius.

Fig. 7(a) illustrates the shear deformation that takes place in the

chips while conventionally cutting a ductile material. The main

shear deformation takes place within the shear plane, whereas the

secondary shear deformation is a result of the friction between the

chip and the tool. In conventional cutting, the deformation zone re‐

sulting from secondary friction is oriented in the opposite direction

of the chip flow. This leads to the production of a shear flow shape,

as illustrated in the figure. The shear flow is influenced by the ellip‐

tical trajectory of the cutting tool and the reversal of the frictional

direction. The shear angle (фE VC) in ultrasonic elliptical vibration

cutting (UEVC) is typically greater than in conventional cutting be‐

cause of the elliptical tool path. Fig. 7(b) demonstrates that a great‐

er shear angle leads to a decrease in chip thickness, which in turn

leads to a decrease in milling force. UEVC is a cutting technique

where the cutting process occurs in an elliptical path within a plane

that includes the cutting and chip flow directions, as illustrated in

Fig. 8. In the case of brittle materials (as shown in Fig. 8(a)), the

UEVC technique utilizes a greater tool amplitude in the thrust di‐

rection, leading to a larger uncut chip thickness (tu c) compared to

typical cutting. The UEVC method applied to ductile materials (as

shown in Fig. 8(b)) results in the formation of smooth and continu‐

ous chips due to the workpiece material's ability to deform without

breaking. While the overall shape of the chip seems comparable in

Fig. 7(a) and 8(b), there is a variation in the shear flow within the

chip. UVAC of materials that can bend without breaking, friction

between the material and the tool causes a distortion in the shear

flow lines along the elliptical direction of the tool, compared to the

direction of cutting 83.

The determination of chip thickness parameters in UVAMM is

influenced by two primary criteria 67-69: 1) The free time ratio (FTR)

refers to the period in which the tool is not actively removing mate‐

rial in cutting mode. The measurement of the cut area is of utmost

importance, and the proportion of time during which cutting does

not occur is referred to as the FTR in 2-D UVAMM. It can be ex‐

pressed in writing form.

FTR = Tnocutting

Tvalidtime

× 100% (3)

Tnocutting refers to the duration during which the tool tip is present in

the cutting region without cutting, whereas Tvalidtime indicates the

overall duration during which the tool tip is present in the cutting

area. FTR is influenced by the vibration and cutting conditions. En‐

hancing FTR by the optimization of vibration and cutting settings

leads to improved chip evacuation conditions, enhanced cutting ac‐

curacy, and improved tool life 34. 2) The amplitude ratio (AR) ad‐

dresses the issue of variations in the distribution of chip thickness

in 2-D UVAMM, particularly noticeable during micro milling. AR

analysis is utilized to calculate the extent of these variations, which

is technically defined as

AR = Avibration

× 100% (4)

The term Avibration refers to the maximum magnitude of the chip thick‐

ness, while fzrepresents the feed per tooth. Minor tool-workpiece

collisions influence material removal, but greater AR values result

in more significant collisions. When collisions exceed critical lev‐

els, they might cause damage to the tools. This emphasizes the im‐

portant function of AR as a factor that reflects and influences the 2-

D VAMM process.

Several researchers conducted a study on the chip formation

mechanism in UVAMM, providing valuable insights and methodol‐

ogies. Zhang et al. 73 developed a technique to measure tool vibra‐

tion in real-time by employing differential equations of motion.

This method enables the addition of process damping effects as

feedback to control the undeformed chip thickness. Yuan et al. 78 in‐

vestigated the impact of cutting conditions on chip formation in

UVAMM and made a comparison with CMM. Their findings dem‐

onstrated that without ultrasonic vibration, chips of considerable

Fig. 6 Illustration of Chip formation process in UVAMM (a) Effect of

chip deformation (b) Increases hin cutting.

Fig. 7 Chip formation mechanism83 (a) Ductile material in conventional

cutting (b) Effect of the shear angle on the chip thickness.

Fig. 8 Illustration of chip formation mechanism in elliptical vibration

cutting83 (a) brittle material (b) ductile material.

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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length and spiral shape were generated. However, the application of

ultrasonic vibration causes a conversion of spiral chips into C-

shaped chips, an improvement that becomes particularly evident

when the amplitude to feed ratio (A/fz) exceeds 1/2. This observa‐

tion suggests a transition from a continuous cutting phase to an al‐

ternating cutting mode. In a study conducted by Li et al. 84 chip

morphology was compared between CMM and UVAMM by experi‐

mental methods. Their investigation focused on the form of chip

breakage and its effect on the bottom of the groove. The findings in‐

dicated that vibration had an important effect on the chip's morphol‐

ogy, resulting in variations in wrinkle height across several regions,

as shown in Fig. 9(a). This phenomenon is caused by the constant

variation of the undeformed cutting thickness during the cutting

process, leading to periodic variations in the shape of the chip.

Chen et al. 85 studied the effect of various vibration frequencies on

the chip breaking mechanism of UVAMM. According to their re‐

search findings, continuous chips were created without any obvious

cracks when there was no vibration present. However, raising the

frequency of elliptical vibration from 6 kHz to 30 kHz results in a

change in the location where cracks start, moving from the vicinity

of the cutting edge to the area of shear and ultimately upwards. Fur‐

thermore, cracks become more prominent causing the chips more

susceptible to cracking and ultimately resulting in the formation of

irregular chips, as shown in Fig. 9(b).

Kiswanto et al. 47 specifically studied the modeling of chip shape

in the context of 2D UVAMM. They constructed a theoretical mod‐

el of the chip's shape using MATLAB, considering the position of

the cutting tool's edge both before and after the application of ultra‐

sonic vibration in the X-Y dimension. In addition, the model has a

variable known as the bottom cutting edge angle that accurately

represents the features of the cutting edge. Kim and Loh83 investi‐

gated the microscopic features of chip generation in V-shaped

groove with the use of elliptical vibration. The researchers conduct‐

ed a comparison between the findings obtained via CMM and UE‐

VAMM. They observed that CMM yielded chips with greater thick‐

ness and a wider radius of curvature compared to those made by

UEVAMM. UEVAMM is anticipated to generate continuous chips

since the depth of cut exceeds the magnitude of the elliptical tool

path. However, the expansion of chip curvature is restricted. This

phenomenon is caused by the counter-directional secondary friction

in the shear deformation zone and the rise in shear angle, which

functions as a chip breaker and results in the creation of discontinu‐

ous chips. Studies suggest that as the friction between the cutting

tool and the chip reduces, the shear angle increases and the chip

thickness reduces.

The investigations on UVAMM chip formation provide useful in‐

sights into the complex relationship between cutting parameters, vi‐

bration characteristics, and material properties. Through compre‐

hension of these relationships, we may enhance the UVAMM pro‐

cess to optimize chip control, surface finish, and overall machining

performance.

2.3. Burr formation

Burr formation is like chip formation and is a common phenome‐

non in the machining process. Fig. 10 shows that it is a significant

factor when evaluating machined surfaces. Burrs are formed

through the plastic deformation of the material towards the comple‐

tion of the cutting process. Various factors influence the production

of burrs, such as cutting parameters, tool geometry, workpiece ge‐

ometry, manufacturing process, and material properties 41,7 8 as illus‐

trated in Fig. 11. Burrs have a negative effect on the life of the prod‐

uct and the precision of the processing. Therefore, further deburr‐

ing or edge finishing techniques are frequently necessary, however

these methods can be expensive and ineffective. Furthermore, the

deburring procedure has the potential to produce unnecessary resid‐

ual tension and potentially cause damage on the component. More‐

over, the deburring procedure becomes more complex for micro

components due to their smaller size, and these parts are very prone

to damage during machining, resulting in their removal as waste.

The first investigations on the phenomenon of burr development

during machining processes can be tracked back to the 1970s 86.

These experiments demonstrate that the metal cutting area experi‐

Fig. 9 Chip breaking in UVAMM (a) Li et al. 84 (b) Chen et al. 85

Fig. 10 Top burr on the micro milled surface in brass (CuZn39Pb2) with and without vibration from 0-15kHz frequency.52

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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ences substantial shear deformation when subjected to the tool's ac‐

tion, leading to notable shear forces and plastic deformation during

the cutting process. Burrs are formed because of residual material

remaining on the workpiece during the cutting process. Regarding

burr production, the processing of burrs can be categorized into

four types: rollover burr, tear burr, cut-off burr and Poisson burr, as

illustrated in Fig. 12. Rollover burr: These burrs referred to as exit

burrs, are conical shape that typically develop at the last stage of

the machining procedure. Tear burr: These burrs result from the ma‐

terial tearing from the workpiece, rather than being removed by

shearing. They are comparable to the burrs that form during the

stamping process. Cut-off burr: These burrs formed from the early

separation of the workpiece from the raw material before the com‐

pletion of the cutting process. Poisson burr: These burrs develop

due to the material's tendency to expand horizontally when subject‐

ed to compression, leading to irreversible plastic deformation.

In another approach burrs can be categorized according to their

shape, position, and formation method. These categories include en‐

try burrs, exit burrs, side burrs, and top burrs 89 as illustrated in Fig.

13. The four types of burrs show differences in both size and the

mechanisms by which they are formed. The top burrs, which are

generated by Poisson burrs and tear burrs, can be found on the up‐

per surface of the workpiece. After the milling operation is complet‐

ed, exit burrs adhere to the machined edge, whereas side burrs ad‐

here to the newly formed surface 90.

The edge radius or edge radius ratio of the cutting tool plays an

important role in micromachining. In contrast to conventional ma‐

chining, where the edge radius may be ignored but the edge radius

plays a key role in micromachining and has a notable impact on the

cutting process 92. As illustrated in Fig. 14, at high cutting speed

(vw), the cutting layer approaching the cutting-edge results in the

generation of chips along the shear sliding surface OD by compres‐

sion and shear deformation. However, the impact of the effective

rake angle (- γn) on chip formation and burr formation is more sig‐

nificant than that of the nominal rake angle (γ0), due to the exis‐

tence of the cutting-edge radius (re). The material is unable to travel

along the OD plane within the cutting-edge radius. Instead, it is

pushed out by the AB area, resulting in the formation of the ma‐

chined surface. The Δhlayer indicates the height at which elastic re‐

covery occurs. As the cutting tool approaches the edge of the work‐

piece, plastic deformation occurs, resulting in a negative shear

zone. This causes part of the workpiece to shift because it lacks sup‐

port from the surrounding material. The negative shear zone is sub‐

sequently connected to the positive shear zone. Burrs in plastic met‐

als primarily develop due to the plowing force exerted following

the removal of chips 93,94.

One interesting finding from this analysis is that burrs mainly

form close to the outer edges or surfaces of the workpiece material

because of the negative shear zone. To avoid the creation of burrs,

it is crucial to minimize negative shear zones, particularly near the

edges of the workpiece. An innovative strategy to address the diffi‐

culty of reducing the cutting-edge radius is to utilize support materi‐

als to strengthen the boundaries of the workpiece. Fig. 15 demon‐

strates that the process of placing support material onto the work‐

piece and enveloping it in a thin layer is an excellent method for

transferring burrs from the workpiece to the support material. By

eliminating the support material, it is possible to achieve a surface

that is free of burrs, while still preserving the original geometry of

the workpiece, such as maintaining perfect angles at the edges 93.

Fang et al. 82 proposed a formula to calculate the burr height in

micro milling.

Bw=1

n∑

i= 1

Δwi(5)

where nrepresent the number of positions, Bwis the average value

of burr width and wiis burr width of the ith point.

The researchers investigated the reduction in burr formation in

Fig. 11 Factors Influencing on burr formation.78

Fig. 12 Illustration of Poisson burr, tear burr and rollover burr.87,88

Fig. 13 Types of burrs in micro end milling.86,87,91

Fig. 14 Burrs formation mechanism in mic ro milling. 9 3 (a) The effect of

ratio of edge radius to depth-of-cut on burr formation. (b) Initiation of

burr formation. (c) Development of burr formation. (d) Final formation

of burr.

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UVAMM in comparison to CMM. Kim and Loh83 conducted a

study on the micro-V-shaped groove processing of copper. They

used a cutting depth of 20μm and a cutting speed of 5 mm/s. The re‐

searchers also investigated the formation mechanism of exit burrs.

They noted that UEVC did not cause exit burrs, whereas CMM mi‐

cro-V-grooving resulted in exit burrs due to the cutting tool moving

away from the workpiece. Chen et al. 35 investigated the method by

which UVAMM reduces errors. The researchers conducted kinemat‐

ic analysis and finite element modeling of microgroove milling. It

was discovered that the tool consistently moved up and down the

side of the groove because of the vibrations that helped it move in

the feeding direction. This minimizes the burr formation. Both sim‐

ulation and experimental data validate that the presence of vibra‐

tions during the micro milling process leads to a significant reduc‐

tion in top burrs on the down-milled side of the slot, in comparison

to the CMM. Li et al. 95 investigated the impact of vibration parame‐

ters on the formation of exit burrs. It was observed that the size of

the exit burr increased as the diameter expanded from 18 mm to

25 mm, and as the vibration frequency increased from 2 kHz to

4 kHz. This occurs due to an enhancement of vibration frequency

within the 2-4 kHz range, resulting in a more prominent plowing

impact on the surface of the workpiece. This effect is accompanied

by the creation of secondary cutting edges. Additionally, this alters

the form of the chips generated during the process of machining. At

a vibration frequency of 10 kHz, the size of the exit burr reduces to

3mm. Increased vibration frequency leads to a higher cutting speed,

exceeding the rate at which the workpiece deforms. This results in

improved chip breaking and a decrease in the production of burrs.

As the vibration amplitude increases from 1 mm to 4 mm, the size

of the exit burr reduces from 22 mm to 2 mm. Li and Wang 36 per‐

formed slot micro-milling experiments using up-milling technique

with complete immersion and vibration. It was discovered that

burrs developed on one side of the machined surface, whereas

down-milling burrs formed on the opposite side. The production of

burrs is not considerably influenced by the rate at which the materi‐

al is fed. The burrs produced during up milling are extremely small,

similar in size to UVAMM and CMM. The presence of mounting

burrs was slightly reduced across all feed rates in the UVAMM sys‐

tem. After completing the cutting experiments with a cutting length

of 168 mm, the up-milling burrs in UVAMM were found to be re‐

duced by 16.0%, 17.5%, and 18.6% compared to CMM. Ding et

al. 49 investigated the impact of size on the formation of top burr in

2D UVAMM. It was discovered that the amount of feed per tooth

greatly impacts the height of the top burr. Additionally, employing

vibration-assisted cutting in micro-end milling can reduce the size

effect and enhance cutting efficiency, resulting in a reduction in the

height of the top burr. Furthermore, the careful selection of suitable

vibration parameters can significantly reduce the height of the up‐

per burrs. Fang and Zhang 48,78 conducted a study on the mechanism

of burr formation in CMM and UVAMM. They used simulation

techniques to investigate this process and then validated their find‐

ings through comparable experiments. It was discovered that em‐

ploying high-frequency ultrasonic vibration in the direction of mill‐

ing feed can decrease cutting temperature and cutting force, en‐

hance chip breaking capability, and reduce burr formation. Han et

al. 96 evaluated the impact of horizontal ultrasonic vibration on the

formation of burrs in UVAMM. Their investigations shown that

horizontal vibrations can change the burr shape from a larger clus‐

ter to a unified sheet-like structure that rests on micro-grooves. En‐

hancing the magnitude of vibration reduces the rise of the side

burrs and breaks them into small pieces. Furthermore, the imple‐

mentation of horizontal vibration has the advantageous effect of re‐

ducing the length of burrs in micro-milling grooves, particularly

when the feed rate exceeds the minimum cutting thickness by a lit‐

tle range. He et al. 74 conducted a comparison between UVAMM

and EUMM, which involves the use of electric fields to induce ul‐

trasonic vibrations during micro milling. Both procedures assist in

the removal of burrs during the process of machining. It is impor‐

tant to mention that EUMM does not exhibit significant burr forma‐

tion on both sides of the microchannel, resulting in a significant en‐

hancement in processing quality. The average burr length at a rota‐

tional speed of 60,000 rpm for EUMM is just 15 µm, in compari‐

son with 58 µm for UVAMM and 361 µm for CMM.

2.4. Tool wear

During machining, the cutting tool and the workpiece experience

significant friction because of direct metal-to-metal contact. The

friction generated at tool contact surfaces results in significant

stress and heat, ultimately causing inevitable tool wear. Damaged

tools will have a negative impact on the precision of machining and

the quality of the surface, leading to a decrease in cutting effective‐

ness and an increase in machining costs 97,98. Optimizing the service

life of tools and maintaining the quality of products are important

for establishing efficient and effective machining operations. Opti‐

mizing cutting parameters is a widely used technique to reduce tool

wear and improve the tool life 99 -101. However, the efficiency of this

method has limitations by conventional machining. Vibration-assist‐

ed machining provides an achievable solution for minimizing tool

wear. By adding vibration into the machining process, both the tool

and workpiece undergo regular cycles of separation and contact, re‐

sulting in a decrease in total friction and wear 102,10 3. Fig. 16 shows

the application of vibration can reduce tool wear in micro milling.

Tool wear can be classified into two different types: abnormal

wear and normal wear, as graphically illustrated in Fig. 17. Abnor‐

mal wear typically occurs due to impact or uneven heating during

processing, leading to brittle damage such as chipping, cracking,

spalling, or deformation. Normal wear is a steady phenomenon

Fig. 16 Tool wear 104 (a) CMM (b) UVAMM.

Fig. 15 Burrs prevention mechanism in micro milling. (a) Pretreatment

with support material. (b) Burr existence in support material. (c) Re‐

moval of support material. 93

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characterized by the gradual degradation of tools as time passes.

The phenomenon of rake tool wear, flank wear, tool tip wear, and

boundary wear during machining can be due to friction and temper‐

atures. 105.

UVAMM has significant advantages in improving tool life. The

efficiency of reducing tool wear is dependent upon the precise cut‐

ting process, which is influenced by varying tool-workpiece separa‐

tion conditions. Zheng et al. 50 proposed that UVAMM has the capa‐

bility to establish three distinct and continuous states of separation

between the tool and the workpiece. These conditions are illustrat‐

ed in Fig. 18. To establish the initial separation between the tool

and workpiece, the vibration velocity of either the tool or work‐

piece (Vv) must exceed the nominal cutting speed (Vn). The term

"nominal cutting speed" refers to the pace at which the tool tip

moves without any assistance from vibrations. The standard can be

expressed in this way:

[ ]

Vv= 2πfxAxcos

( )

2πfxt+φxcosα≥é

Vn=πrn

30 (6)

cos

( )

2πfxt+φxcosα≥rn

60fxAx

(7)

Eq. (7) is only valid when

60fxAx

≤1(8)

In the above equations, fxand Axrepresent the vibration frequen‐

cy and amplitude, respectively, whereas φxis the initial vibration

phase angle.

A comprehensive investigation has been conducted on the phe‐

nomenon of tool wear in CMM. Wang et al. 106 and Dawodinejad et

al. 107 conducted thorough research on tool wear in micro-milling,

specifically investigating its impact on surface roughness and chip

formation. However, only a limited number of research have inves‐

tigated its behavior with the assistance of ultrasonic vibrations.

Greco et al. 51 conducted a comparison between UVAMM and

CMM and observed that whereas CMM tools exhibited noticeable

wear on the main cutting edges and corners, vibration reduced this

wear, as shown in Fig. 19(a). The absence of built-up edge forma‐

tion and tearing during UVAMM is the cause of this decrease in

wear. Fang and Yuan 82,108 conducted an analysis of tool wear in

UVAMM and discovered that vibration decreased the occurrence of

built-up edge development on the rake face of the cutting tool, as

shown in Fig. 19(b).

Chern et al. 34 observed that employing vibration assistance in

micro milling can enhance the production of grooves within the ac‐

ceptable tolerance range. Without any vibration, the tool's life is

limited to just 80 grooves. However, when subjected to an ultrason‐

ic frequency of 500 Hz and an amplitude of 10μm, the tool’s life

improves to 98 grooves, indicating an approximate increase of

22%. Ibrahim et al. 109 conducted a comparison of tool wear be‐

tween UVAMM and CMM. According to their study, applying a

piezoelectric actuator to transmit small-scale vibrations and oscillat‐

ing frequencies to the workpiece generates a tiny space that effi‐

ciently breaks down heat through the chip. Additionally, they dis‐

covered the complex tool path mechanism of 2D UVAMM, in

which the proximity of the tool tip to the workpiece surface is influ‐

enced by the amplitude displacement along the applied frequency.

By selecting the suitable amplitude and frequency, 2D UVAMM ef‐

fectively minimizes tool wear and enhances surface roughness in

comparison to CMM. Zheng et al. 50 investigated the process by

Fig. 20 Comparison of tool flank wear in CM M and UVAMM for different cutting length.

Fig. 19 Comparison of tool wear in CMM and UVMM (a) Greco et al. 51 (b) Fang et al. 82

Fig. 17 Classification of tool wear.

Fig. 18 Three types of tool workpiece separation conditions.50

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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which tool wear is reduced in non-resonance-assisted micro-mill‐

ing. They employed a coated micro-milling cutter to manufacture

Ti6AL4V at three distinct vibration frequencies (high, medium, and

low) after analyzing the tool's separation from the workpiece. The

experiments focused on the cutting conditions, specifically if the

tool was removed from the workpiece. Their findings showed that

UVAMM efficiently reduces tool wear by employing various mech‐

anisms which restrict wear. Li et al. 84 conducted a comparison of

the tool wear in CMM and 2D UVAMM. The researchers discov‐

ered that the main characteristic of CMM tool wear is adhesive

wear specifically occurring at the tip of the tool. Extended cutting

operations, coupled with elevated temperatures and forces, may

damage the cutting edge, resulting in a loss of its material-cutting

capabilities. Conversely, the wear pattern of UVAMM shows nota‐

ble differences. The material sticks to the edge of the cutting tool,

resulting in adhesive wear. The phenomenon of micro-grinding oc‐

curs because of the cutting process, leading to a significant buildup

of material on the side surface of the cutting edge. Subsequently,

the material actively engages in the cutting procedure, so enhanc‐

ing the quality of the surface. Li et al. 36 investigated the impact of

tool wear on the tool life in UVAMM. It was discovered that in‐

creasing the cutting length had an impact on cutting performance

when small amplitudes (2μm) were applied to microtools, namely

due to tool flank wear. However, when the cutting speed is signifi‐

cantly lower than the maximum vibration speed, tool wear shows

enhancement in comparison to CMM, but when the cutting speed

and cutting length further increase, the ultrasonic vibration intro‐

duces additional vibrations and oscillations to the cutting process,

causing the tool to experience greater forces and heat. These in‐

creased forces and heat can accelerate tool wear and result in short‐

er tool life, as shown in Fig. 20.

2.5. Cutting forces

During conventional cutting, the cutting forces are mainly affect‐

ed by the machining dynamics, without the addition of any addi‐

tional vibration assistance. The forces in discussion are frequently

defined by the one-way movement of the cutting tool, leading to

different force patterns 110. Conversely, ultrasonic vibration cutting

involves the introduction of dynamic oscillations during cutting.

The periodic tool motions generated by ultrasonic vibrations impact

the interaction between the tool and the workpiece. This results in a

more complex distribution of force in comparison to conventional

cutting processes. The combination of ultrasonic vibrations and con‐

ventional cutting forces alters the process of chip creation and im‐

pacts the mechanism of material removal. Hence, the addition of vi‐

bration can result in variations in cutting forces and, in certain in‐

stances, a decrease in the overall force generated on the tool, hence

influencing tool wear and surface finish 111,112. Shen et al. 113 found

that while the maximum cutting force produced by UVAMM can

sometimes be higher than that of CMM, the average cutting force of

UVAMM is significantly lower. This observation remains valid for

both experiments and finite element simulations. Interestingly, the

variations in frequency and amplitude during UVAMM have signifi‐

cant effects on cutting forces. When the frequency increases from 0

Hz, it has a significant impact on reducing cutting forces. The re‐

duction in forces caused by the resonance of the workpiece holder

within this frequency range leads to a significant increase in vibra‐

tional amplitude and, consequently, a higher velocity of the work‐

piece under vibration. When frequency further increases from a

range, the system is no longer excited by vibration, and the vibra‐

tion amplitude decreases again, which results in an increase in the

cutting force 5 2,85. Similarly, when the amplitude increases from

0µm, the trajectory of tool tip 2 starts to be tangent to the trajectory

of tool tip 1. This indicates that a cutting edge begins to intermit‐

tently cut during a cutting cycle, and chips break more effectively,

ultimately reducing the cutting forces 76,108. In addition, the further

increase in amplitude can cause an increase in the cutting forces,

which indicates that it is important to consider intermittent cutting

conditions and impact force while choosing the amplitude. Fig. 21

illustrates the impact of tool vibration on cutting forces in UVAMM.

A comprehensive investigation has been carried out on the mech‐

anisms and models of UVAMM cutting force generation and reduc‐

tion. KIM et al. 12,114 investigated the V-groove's geometry and its

impact on cutting forces in the UVAMM process. It was noted that

the cutting force of UEVAMM were significantly reduced in com‐

parison to conventional V-groove cutting, particularly when milling

depths were smaller. It is important to mention that at a depth of

5μm, the cutting force of UEVAMM is reduced by a factor of four

compared to the conventional approach. While the decrease in

force is not as pronounced when milling at greater depths, such as

25 μm, UEVAMM still manages to achieve a 50% reduction in cut‐

ting force. This demonstrates that the decrease in force is more pro‐

nounced with the use of UEVAMM at lower milling depths. Re‐

searchers explain this phenomenon to the specific energy transfer

mechanism of UEVAMM, which reduces the friction among the

tool, chip, and workpiece. Fang and Yuan 76,82,1 08 conducted a com‐

parison between simulated and experimental cutting forces in

UVAMM and CMM. While the simulated values may somewhat ex‐

ceed the actual forces, the general pattern of reduction in UVAMM

cutting force remains constant. UVAMM effectively decreased all

three force components (Fx,Fy, and Fz) in comparison to CMM, re‐

sulting in reductions ranging from 7.6% to 11.5%. In addition, they

noted that a smaller vibration amplitude also had a significant im‐

pact on reducing cutting forces, and an increase in amplitude was

more effective in reducing cutting forces due to the intermittent cut‐

ting effect. Xu et al. 43,115,116 conducted studies with and without vi‐

bration to directly compare the cutting forces in UVAMM and

CMM. Their findings validated the effectiveness of UVAMM in re‐

ducing cutting forces on various workpiece materials, therefore en‐

hancing machining precision and extending tool life. It is most im‐

portant to note that the increase in amplitude from 0 μm to 4μm has

a significant impact on reducing cutting forces, as shown in Fig. 22.

Hu et al. 117 investigated the unique function of ultrasonic torsion‐

al vibration (UTV) in decreasing cutting forces during ultrasonic

torsional vibration-assisted micro milling (UTVAMM). Their inves‐

tigations demonstrated that the primary cause for the observed de‐

crease in force was the dynamic impact of torsional vibrations. Fur‐

thermore, they hold the belief that the feed per tooth is an important

Fig. 21 Effects of the tool vibration on cutting forces.73

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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variable that influences the reduction of cutting force. They claim a

smaller value of feed per tooth offers a better advantage in terms of

cutting force reduction. Ding et al. 59, 60 developed complex 3D cut‐

ting force models specifically for 2D UVAMM. Their model effec‐

tively predicted cutting forces across different situations by includ‐

ing the dynamic elements of the cutting process. The predicted forc‐

es exhibit a high level of agreement with the actual results, so con‐

firming the precision of the model. Parenti et al. 118 also conducted

a study on the decrease of cutting force in UVAMM. Huan et al. 53

conducted a comparison of the cutting forces between UEVAMM

and CMM. The cutting speed was set at 30 m/min, and the vibra‐

tion frequency was set at 20 kHz. It was noted that UEVAMM

shows significant consistency because of its characteristics of vibra‐

tion. During the milling process, the tool experiences stress concen‐

tration and extrusion, resulting in a substantial rise in cutting force.

However, the UEVAMM exhibited a cutting force that was 60%

lower than that of the CMM, as shown in Fig. 23(a). Greco et al.

51,52 conducted two separate investigations that showed the particu‐

lar cutting force of UVAMM is much less than that of CMM. More

precisely, the UVAMM force varies between 0.0016 and 0.0056 N/

μm, whereas the CMM force varies between 0.011 and 0.082 N/

μm, as shown in Fig. 23(b). In addition, when the frequency in‐

creases from 0 to 3.9 kHz, it helps reduce the cutting forces, but fur‐

ther increases in frequency again increase the cutting forces.

Zhang et al. 4 8 investigated the impact of vibration on cutting

forces during the initial contact between the tool and the work‐

piece. They noticed that the application of vibration led to a rapid

increase in cutting forces because of the initial impact upon con‐

tact. Subsequently, there is a significant decrease, demonstrating

the discontinuous characteristic of the milling procedure in

UVAMM. The discontinuous pattern of this behavior reduces the ef‐

fectiveness of the side plow effect during up milling and causes the

chips to break in advance, ultimately leading to lower average cut‐

ting forces compared to the CMM. Shang et al. 61,119 focused on de‐

veloping 2D UVAMM cutting force models. The researchers stud‐

ied multiple parameters that influence the instantaneous depth of

cut, such as tool runout, size impacts, and cumulative effects. Sub‐

sequently, the model is employed to examine the impact of ampli‐

tude and frequency on cutting forces. Furthermore, they investigat‐

ed the application of UVAMM for the objective of removing bone

material throughout surgical processes, demonstrating the capabili‐

ty of this technology to reduce cutting forces and enhance the

smoothness of bone surfaces during the milling process. Chen et

al. 85 studied the overall cutting force characteristics in UVAMM.

Frequent changes in the cutting force were noticed, and it was dis‐

covered that adding vibration at a frequency of 6 kHz resulted in a

significant decrease in the average cutting force compared to the

CMM. Their findings demonstrated that vibration can efficiently

breakdown chips, thereby reducing total milling forces. Additional‐

ly, it was noted that as the vibration frequency increased, the aver‐

age cutting force decreased even more. The most notable decrease

was noticed at 60 kHz, which can be due to the obvious formation

of material cracks, as shown in Fig. 24. Prabhu et al. 120 analyzed

the distribution of cutting forces (Fxand Fy) during 2D UVAMM at

varying increase frequencies (300 Hz and 600 Hz). Their findings

demonstrated an inverse relationship between the generating fre‐

quency and the cutting force, whereby an increase in the earlier re‐

sulted in a decrease in the latter. Consequently, increasing the fre‐

quency at which the drive operates has the potential to enhance the

performance of the machining process by reducing the forces exert‐

ed during cutting and improving the overall stability of the process.

3.6. Cutting temperature

The temperatures produced during metalworking play an impor‐

tant role in determining the outcome of the cutting process in all its

aspects. It significantly affects the wear and tear of tools, the forma‐

tion of burrs, the mechanisms of chip removal, the quality of surfac‐

es, the stress that remains, the deformation in three dimensions, and

the accuracy of dimensions in microfeatures that have been ma‐

chined 121-123. The cutting temperature in conventional cutting tech‐

niques is mostly determined by the interaction between the tool and

the workpiece during material removal. In conventional cutting, the

cutting temperature typically rises because of the continuous and

one-way cutting motion. This leads to the production of concentrat‐

ed heat at the interface between the tool and the workpiece 124.

Meanwhile, UVAC generates dynamic oscillations when cutting.

The tool experiences periodic engagement and disengagement with

the workpiece due to ultrasonic vibrations, leading to discontinuous

cutting action. The periodic process of tool engagement and disen‐

gagement leads to a distinct heat distribution in contrast to conven‐

tional cutting. By incorporating ultrasonic vibration, the dissipation

of heat is enhanced, leading to a potential decrease in the overall

cutting temperature 125,126. Chen et al. 127 found that the introduction

of ultrasonic vibration effectively enhances the diffusion time and

space of cutting temperature. In addition, it is also evident from pre‐

vious studies that the increase in amplitude and frequency has a sig‐

nificant impact on reducing cutting temperature 77. Fig. 25 illus‐

Fig. 22 Comparison of cutting forces in CMM and UVAMM (a) 6061T6

(b) TC4.

Fig. 23 Comparison of cutting forces in CMM and UVAMM (a) Huan

et al. 53 (b) Greco et al. 52 Fig. 24 Impact of frequency variations on cutting forces in UVAMM.85

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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trates the temperature modeling in UVAM.

While considerable attention has been devoted to the investiga‐

tion of cutting temperature in CMM 128,129, the mechanisms deter‐

mining the generation of cutting temperature in UVAMM remain

unclear. Numerous scholars have initiated an investigation into this

crucial element, offering significant perspectives into its behavior.

Huan et al. 53 conducted a comparison of the cutting temperatures

between CMM and UEVAMM and observed a significant decrease

of 17.6% in the context of UEVAMM, as shown in Fig. 28. This re‐

duction was attributed to the gap between the rake face and the

workpiece during the vibration process, enabling the dissipation of

heat. Conversely, the continuous interaction between the tool and

workpiece in a CMM can result in the accumulation of heat and

high temperatures.

Zhang et al. 4 8 investigated the distribution of the cutting temper‐

ature field in CMM and UVAMM. It was noted that the highest

temperatures were found in the shear deformation zone and then

gradually extended to other areas. UVAMM has a higher immediate

cutting thickness compared to CMM, yet its intermittent nature

minimizes the accumulation of heat. This minimizes the thermal en‐

ergy produced due to friction between the tool and workpiece, al‐

lowing for enhanced cooling efficiency. Ibrahim et al. 109 conducted

a comparison of cutting temperatures between UVAMM and

CMM. The researchers observed the creation of small gaps because

of applying low-amplitude and frequencies to the workpiece using

a piezoelectric actuator. This space facilitates efficient heat dissipa‐

tion of the chip. In addition, their research uncovered the complex

mechanics of the tool path in 2D UVAMM. This involves how the

proximity of the tool tip to the surface of the workpiece is influ‐

enced by the displacement amplitude at the given frequency. Shang

et al. 77 investigated the use of UVAMM in orthopedic surgery, with

a particular focus on bone milling. A temperature model was devel‐

oped for vibration milling of bone materials and its accuracy has

been verified by simulations. According to their research findings,

UVAMM is more effective than CMM in reducing heat generation

and minimizing thermal damage. In addition, the increase in ampli‐

tude from 0 to 4μm and frequency from 0 to 1000 Hz significantly

reduced the temperature at the cutting zone, as shown in Fig. 27.

2.7. Surface morphology and roughness

The surface roughness of the machined surface is closely related

to factors such as the structure of the micro milling tool, the accura‐

cy of the machine tool, the amount of material being cut, the cool‐

ing conditions, and the wear of the tool. Choosing a lower feed rate

may result in a reduction of the residual height of the machined sur‐

face if a smaller cutting edge radius is used 130. Li and Chou 131 em‐

phasized the significant impact of tool wear on surface roughness

in micro milling, irrespective of the cutting conditions. The re‐

searchers discovered that by minimizing tool wear, it is possible to

attain excellent surface quality in micro milling. According to

Shaw 132, state that the surface generated by CMM is influenced by

the accurate replication of the geometric and kinematic characteris‐

tics of the tool tip form factor. In addition, according to Ding et al.

60 state that in a CMM, the cutting tool would accurately replicate

the tool profile on the machined surface as it moves along the actu‐

al tool path, thereby revealing the surface topography of the ma‐

chined object. However, the 2D UVAMM exhibits circular motion

properties that enable the cutting point of the tool to traverse the

Fig. 25 Illustration of temperature generation in UVAM (a) Workpiece side heat source (b) Chip side heat source.126

Fig. 26 Comparison of cutting temperature in CM M and UVAMM.

Fig. 27 Impact of amplitude and frequency variation on cutting temperature in UVAMM.77

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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cutting region of the preceding cycle, thereby eliminating the raised

and lowered portions of material remaining from the previous cy‐

cle. The circular motion of the 2D UVAMM during the cutting pro‐

cess will minimize the impact of average force and enhance surface

accuracy by reducing any vibrations between the tool and work‐

piece. In addition, when considering this viewpoint, decreasing the

cutting forces of the tool also leads to a decrease in vibrations on

the tool, so improving the quality of the surface produced 60,1 09. Ra‐

sidi and Ding discovered that the utilization of 2D UVAMM facili‐

tated the splitting of the machined surface into smaller parts. Simul‐

taneously, these pieces are removed during alternating cycles by uti‐

lizing contrasting frequencies and amplitudes 133. In addition, it is

interesting to note from previous studies that the increase in ampli‐

tude40,108 and frequency104,116 decreases the surface roughness and im‐

proves the surface morphology of the cutting surface. Fig. 28 illus‐

trates the development of surface topography in UVAM and Fig. 29

shows the machined surface in CMM and UVAMM.

Researchers have thoroughly investigated the impact of milling

parameters on the surface integrity and quality of surfaces ma‐

chined using UVAMM. Fang et al. 82 investigated the surface mor‐

phology of grooves that were machined using CMM and UVAMM.

They noticed that surface defects gradually reduced when the feed

per tooth (fz) increased, particularly when the vibration amplitude

was 0 μm. Defects are nearly removed when the value of fzis 5 μm/

z. Low fzvalues result in excessive plastic deformation, causing the

buildup and adherence of material, leading to the formation of

burrs and defects in the surface. When ultrasonic vibration is ap‐

plied with an amplitude of 3 μm and a frequency of 32 kHz, and a

feed speed of 2 μm/z is maintained, the occurrence of pits, ridges,

and grooves is significantly reduced. As the value of fzincrease, the

surface roughness becomes more prominent. However, if the value

of fzreaches 5μm/z, the impact of ultrasonic vibration on surface

quality becomes less pronounced. The decrease in defects is mostly

related to the separation features of the vibration process, which im‐

pact the rate of change in the cutting process and the heating effect.

Lian et al. 37 performed studies using three different ultrasonic vi‐

bration amplitudes to compare the surface quality of machined

grooves with and without vibration. Their findings clearly demon‐

strate that surfaces subjected to UVAMM processing exhibit greater

uniformity and absence of any machining marks, in contrast to sur‐

faces treated with CMM causes micro defects. Chen et al. 71,72 inves‐

tigated the development of various surface textures on the end face

of the workpiece by using different combinations of machining and

vibration parameters. The researchers suggested a technique for

generating surface using a milling process that incorporates vibra‐

tions. They confirmed the efficiency of this method through experi‐

mental testing and showed that when the frequency increased from

0 to 3.4 kHz, the surface morphology improved. Guo Li et al. 84,95

conducted a study on the mechanism of surface development in 2D

UVAMM. They also investigated how this mechanism affects chip

removal efficiency, chip shape, and tool life. The researchers con‐

ducted experimental tests to confirm the accuracy of using vibra‐

tion assistance to enhance the surface integrity and quality of ma‐

chined surfaces. Their findings validated that the utilization of vi‐

bration assistance enhanced the micro step pattern on both surfaces

of the thin-walled micro structured surface and altered the form of

the groove's bottom because of tool eccentricity. Additionally, it

was discovered that the vibration-assisted machined surface exhibit‐

ed a shape deviation of less than 101 nm SPV and a surface rough‐

ness of less than 25 nm RMS. In addition, the increase in frequency

from 2 to 10 kHz and amplitude from 0 to 4μm significantly reduc‐

es the surface roughness, as shown in Fig. 30. Li and Wang36 inves‐

tigated the correlation between surface roughness and cutting

length in UVAMM and CMM. Upon reaching a milling length of

24 mm, the researchers saw that the rate of tool wear in both

UVAMM and CMM became similar. Additionally, at this point, the

surface roughness might be considered as an enhancement in the

obtained surface quality by UVAMM. Thus, the extraordinary effi‐

ciency of UVAMM in the low-speed milling procedure was validat‐

ed, resulting in a reduction in surface roughness by 56.4%, 4.4%,

and 8.6% respectively for a milling length of 24 mm, as shown in

Fig. 31.

Ibrahim et al. 38 discovered that at low frequencies, surface

roughness increases as the frequency increases because of greater

motion in the gap. However, within the ultrasonic frequency range,

the surface roughness reduces because of the reduction in milling

force and temperature. The increased frequency of vibration leads

Fig. 29 Machined surface 104 (a) CMM (b) UVAMM.

Fig. 28 Illustration of surface topography formation in UVAM134

(a) 0-T/2 (b) T/2-T.

Fig. 30 Impact of vibration frequency and amplitude on surface roughness in UVAMM.95

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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to a significant enhancement in surface roughness caused by the in‐

creased gap between the cutting tool and the workpiece. This mini‐

mizes stress during the cutting process, enhancing cutting precision

and lowering deformation, thereby decreasing the formation of

burrs on the surface of the tool. Kiswanto et al. 135 proposed a theo‐

retical model for surface roughness of UVAMM using the MAT‐

LAB software. This model accounts for the influence of the tool's

bottom tip angle on the surface of the workpiece and can be em‐

ployed to replicate the effects of UVAMM on the workpiece sur‐

face. Guo et al. 136 developed a machining system that utilizes vibra‐

tions to assist in the process. The system includes a worktable that

is not resonant, allowing for the adjustment of the vibration fre‐

quency. The researchers conducted orthogonal experiments to in‐

vestigate the impact of feed speed, vibration frequency, and ampli‐

tude on surface quality. Their findings shown that increasing the vi‐

bration frequency reduced the formation inaccuracy and roughness,

whereas the amplitude enhanced the surface quality only within a

particular range. The accuracy of a 3D surface shape simulation

model of UVAMM developed by Yan et al. 40 was verified by exper‐

iments. The model offers valuable insights into the process of sur‐

face development under UVAMM, and the surface morphology im‐

proved on the cutting surface when the amplitude increased from 0

to 3μm. Xu et al. 43,116 reported that ultrasonic vibration decreased

surface defects, leading to an enhancement in surface quality. In ad‐

dition, they found a vibration-induced delay in the micro milling

process and a reduction in surface roughness when the amplitude

increased from 0 to 4μm, as shown in Fig. 32.

Tan et al. 54 conducted a comparison of the surface characteristics

of microgrooves that were machined using CMM and UEVAMM.

It was discovered that the CMM machined surface had surface de‐

fects such as ridges, cavities, and rip lines, but the UEVAMM ma‐

chined surface had no such defects. Huan et al. 53 found that UE‐

VAMM offered improved surface quality in comparison to CMM.

The reduced surface roughness was due to the presence of move‐

ments nanoparticles in the matrix. Jin et al. 137 evaluated the im‐

pact of vibration direction, range, and frequency on surface rough‐

ness and profile in UVAMM. It was discovered that continuous vi‐

bration had the greatest effect in enhancing surface quality. Fur‐

thermore, the use of vibration assistance was discovered to im‐

prove the brittle transition of the glass film and reduce surface

damage, as shown in Fig. 33(a). Du et al. 138 developed a compre‐

hensive approach for predicting the vibration and surface rough‐

ness of micro-end mills. Their model addresses the accurate mo‐

tions followed by the cutting edge, the vibrations of micro-end

mills that depend on their size, and the elastic recovery of the ma‐

terial. The findings indicate that the vibration of micro-end mills

leads to an increase in both micro-milling forces and surface

roughness. This has been confirmed through experimental verifica‐

tion. Yuan et al. 76,108 studied the impact of UVAMM on surface

quality by employing workpiece vibration machining. Their find‐

ings demonstrated that reducing milling speeds, feed rates, and

employing moderate vibration amplitudes resulted in the most fa‐

vorable surface morphology, as shown in Fig. 33(b). The mor‐

phology of this structure exhibits a consistent and symmetrical

fish scale pattern, characterized by a smooth surface with mini‐

mum roughness and an absence of defects. Enhancing the surface

quality was achieved by optimizing the cutting settings, namely by

increasing the cutting speed to 37.68 m/min and adjusting the feed

per tooth to 6 μm. He et al. 74 introduced electrically assisted ultra‐

sonic micromachining (EUMM) as a remedy for the issue of ele‐

vated surface roughness in workpieces. Their findings demonstrat‐

ed that the implementation of EUMM led to a significant decrease

in surface roughness. The EUMM method yielded a reduced bot‐

tom surface roughness (0.33 µm) compared to both the UVAMM

and CMM methods. EUMM enhances the smoothness of the side‐

walls by utilizing particles throughout the manufacturing process,

resulting in a minimal surface roughness of 0.34 µm on the vertical

sidewalls.

Fig. 31 Comparison of surface roughness in CMM and UVAMM.

Fig. 33 Surface morphology comparison in CMM and UVMM (a) Jin et al. 137 (b) Yuan et al. 76

Fig. 32 Impact of amplitude on surface roughness in UVAMM.43

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3. Finite element sim ulation of machining process

The finite element approach is an effective tool for simulating

the cutting process. When compared to physical testing, using this

approach can greatly reduce costs and save time. It also enables the

identification of an effective and practical production process at an

early stage. Moreover, it offers useful perspectives on enhancing

the characteristics of the cutting process. The progress in computer

software and hardware has greatly improved the capabilities of fi‐

nite element analysis (FEA) software, resulting in a major increase

in research efficiency.

To study UVAMM mechanism and compare the results with

CMM, many researchers have used ABAQUS 117 and Deform 48

software to develop detailed 2D and 3D finite element simulation

models, which can be seen in Fig. 34.

Hu et al. 117 developed a thermomechanical coupled model of

UVAMM using the ABAQUS software. This work offers signifi‐

cant insights into the role of feed per tooth in reducing cutting forc‐

es during the UTVAMM process. The research findings can be em‐

ployed to enhance the UTVAMM process by increasing machining

efficiency and minimizing tool wear. In another study, Hu et al. 139

developed a 2D finite element (FE) model of UVAMM using

ABAQUS software. This study offers significant insights into the

mechanism of UVAMM and the impact of process parameters on

the performance of the manufacturing process. The results can be

utilized to enhance the UVAMM process to optimize machining

precision, surface quality, and reliability of micro-components.

Chen et al. 85 developed a 2D FE model for the simulation of UE‐

VAMM. This model simplifies the milling process by assuming

that the workpiece keeps stationary while the micro milling cutter

rotates. The simulation findings indicate that the elliptical vibration

of the milling cutter leads to the formation of micro-texture on the

milling surface. This study offers significant insights into the mech‐

anism of UEVAMM and its prospective benefits for micro milling

applications. In a subsequent study, Chen et al. 140 performed a com‐

prehensive investigation of the fundamental milling process of

UVAMM by combining FE simulation and experimental tests. A

UVAMM FE model of magnesium alloy was created, employing

the Johnson-Cook material model. Through an investigation of the

size effect and material removal mechanism of UVAMM, it was de‐

termined that the vibration frequency has a substantial influence on

the machining process. They found that by increasing the vibration

frequency, they were able to successfully reduce burr formations,

cutting forces, and tool wear. The accuracy of these discoveries is

supported by the results of finite element simulation and experi‐

mental validation. Zheng et al. 50 utilized FE simulation and experi‐

mental techniques to investigate the mechanism of tool wear reduc‐

tion in non-resonance-assisted micro-milling. A UVAMM FE mod‐

el was developed using the ABAQUS software, which integrated a

Johnson-Cook material model and a damage model. The results

show that UVAMM is highly successful in minimizing tool wear by

employing numerous mechanisms that prevent wear. Zhang et al. 48

developed a 3D FE model using Deform software to investigated

the mechanism of burr formation in CMM and UVAMM. They sub‐

sequently carried out experiments to validate their findings. Accord‐

ing to their research, the application of high-frequency ultrasonic

vibration in the milling feed direction can successfully decrease cut‐

ting temperature and forces, enhance chip breaking capability, and

thus minimize the burr formation. The experimental results further

validated the precision of the simulation results and offered useful

parameter guidance. Huan et al. 53 investigated the cutting character‐

istics of ultrasonic vibration using a 2D thermodynamic coupled fi‐

nite element milling model. The researchers discovered that ultra‐

sonic elliptical vibration cutting outperformed conventional cutting

in terms of surface profile, average milling force, and milling tem‐

perature, as presented in Fig. 35. During the cutting process, the

stress is generally applied horizontally, and the removal of material

particles primarily occurs through cutting.

Fang et al. 82 highlighted the application of FE simulations for

the prediction of cutting forces. The milling forces derived from

simulations and experiments were effectively compared, thus con‐

firming the accuracy of the model. Lu et al. 141 developed a 2D FE

model of UVAMM using ABAQUS software. Their approach inte‐

grates the Johnson-Cook flow stress model and shear failure princi‐

ples of the workpiece material, along with the modified Coulomb

friction law that includes both sliding and bonded components. The

researchers conducted a study using FEA to investigate the impact

of cutting parameters, vibration parameters, and tool shape on the

process. Furthermore, they conducted an analysis of the residual

levels of stress in various tool flank wear conditions, offering use‐

ful insights for the enhancement of process parameters, the im‐

provement of product performance, and the optimization of tool

life and reliability. Shang et al. 77 developed a 3D FE temperature

model using ABAQUS software for bone material in UVAMM and

compared with CMM, as shown in Fig. 36. The validity of their

Fig. 35 Surface morphology by FEA (a) CMM (b) UVAMM.

Fig. 34 Finite element simulation models (a) Deform 3D model (b)

ABAQUS 2D model (c) ABAQUS 3D model.

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model was confirmed using FEA simulations, emphasizing the po‐

tential of FEA in examining thermal behavior in UVAMM applica‐

tions.

4. Significance of MQL in UVAMM

The main goal of employing cooling lubricants in machining is

to enhance the quality and efficiency of the final products. Studies

have demonstrated that the use of significant coolants and lubri‐

cants can enhance surface quality, reduce tool deterioration, and

minimize cutting forces. In addition, they assist in minimizing ther‐

mal deformation, hence enhancing the precision of the design and

ability to remove chips 142,1 43. Although conventional cooling lubri‐

cants offer numerous advantages, they represent an important chal‐

lenge due to their negative impact on the environment and human

health. As a result, there has been a growing focus on the develop‐

ment of eco-friendly alternatives, such as minimum quantity lubrica‐

tion (MQL), and cryogenic cooling 144. In MQL, a small quantity of

lubricant is directed toward the cutting zone in the presence of air 145.

Only two studies were conducted in UVAMM by applying the

MQL, and they showed a significant impact of the MQL on machin‐

ability improvement. Hence, additional study is necessary to fully

understand and maximize its potential advantages in UVAMM. Li

and Wang36 investigated the impact of MQL on tool wear during

UVAMM and made a comparison with dry cutting. Their findings

show that the utilization of MQL significantly reduced tool wear,

thus improving cutting performance in relation to surface rough‐

ness and the formation of burrs, as shown in Fig. 37. Ibrahim et al.

38 conducted research to investigate the impact of MQL on the pro‐

cessing performance of UVAMM. It was noted that the use of

UVAMM alone enhanced the quality of machining, but the addition

of MQL resulted in further improvements in mechanical accuracy.

This implies that MQL can enhance the beneficial impact of

UVAMM on dimensional precision, leading to improved machining

results.

5. Advantages of UVAMM for difficult-to-cut

materials

UVAMM is an innovative machining technique that uses CMM

with high-frequency vibration. UVAMM offers outstanding versatil‐

ity beyond its ability to manage complex geometries. The versatili‐

ty of this method is seen in its extensive compatibility with diffi‐

cult-to-cut materials, such as titanium alloys 84, steel alloys 104, nick‐

el-based alloys 108, aluminum alloys 61, composites 116, brass 52, and

optical glass 137 . Fig. 38 summarizes the properties that make these

materials difficult to cut. In addition, these materials are widely

used in biomedicine, optics, aerospace, semiconductors, and other

fields because they have excellent physical, chemical, and mechani‐

cal properties 146-152. Based on research, it can be found that pub‐

lished reports mainly focus on cutting characteristics, cutting forc‐

es, surface quality, and subsurface damage. Compared with CMM,

UVAMM has shown good performance, as presented in Table 2.

This compatibility allows for the efficient manufacturing of high-

quality products.

6. Conclusion

This article presents a comprehensive review of the latest devel‐

opments in ultrasonic vibration-assisted micro-milling (UVAMM).

It specifically focuses on various aspects, such as UVAMM pro‐

cessing, which include mathematical modeling, chip formation,

burr formation, tool wear, cutting forces, cutting temperature, and

surface morphology; the finite element simulation of UVAMM; the

significance of MQL in UVAMM; and applications of UVAMM for

difficult-to-cut materials such as titanium alloys, steel alloys, nick‐

el-based alloys, aluminum alloys, composites, brass, and glass. The

following possible conclusions can be drawn from this review:

(1) Micro-milling demonstrates exceptional proficiency in creat‐

ing complex 3D shapes on various materials, although it encounters

Fig. 37 Significance of MQL in UVAM M.

Fig. 38 Properties of the materials that make them difficult to cut.146-152

Fig. 36 Temperature nephogram of bone material by FEA (a) CMM (b) UVAMM.

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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multiple challenges when it comes to difficult-to-machine materi‐

als. UVAMM is a promising technology that can effectively tackle

these challenges while achieving a wide range of applications for

difficult-to-machine materials.

(2) UVAMM improves chip breaking properties, reduces burr

formation by creating variations in chip thickness across different

regions, and promotes natural breakage.

(3) UVAMM effectively addresses the issues related to tool wear,

cutting forces, cutting temperature, and surface roughness encoun‐

tered while machining challenging materials. By conducting experi‐

ments and utilizing models, we may make precise predictions and

optimize these factors to attain exceptional outcomes. The periodic

cutting movement produced by UVAMM vibration enhances the

service life of the tool, reduces forces and temperatures, and en‐

hances the quality of the surface finish.

(4) Advancements in hardware and software have pushed finite

element analysis (FEA) to unprecedented levels, greatly enhancing

research productivity. The FEA model developed by UVAMM also

exhibited enhanced precision, offering important insights into the

improvement of the process.

(5) The UVAMM has great potential on its own, and the addition

of MQL further enhances its overall efficiency, establishing it as an

effective strategy for achieving precise micromachining.

(6) UVAMM demonstrated its versatility by smoothly working

with a diverse range of materials, such as titanium alloys, steel al‐

loys, nickel-based alloys, aluminum alloys, composite materials,

brass, and optical glass. This adaptability allows to produce better

products that enhances efficiency across numerous applications.

Table 2 Research summary of the difficult-to-cut materials in UVAMM.

Greco et al. 52

Fang et al. 82

Xu et al. 116

Li et al. 95

Greco et al. 51

Xu et al. 43

Han et al. 96

Yuan et al. 108

Yuan et al. 78

Zhang et al. 48

Brass (CuZn39Pb2)

Inconel718

Graphene-based alumi‐

num matrix composite

Al6061 aluminum alloy

AISI 316L

TC4 titanium alloy and

6061T6 aluminum alloy

304 austenitic stainless

steel

Inconel718

The comparison with CMM revealed a substantial 63% decrease in cutting forces,

reduced burr formation, and improved surface quality, indicating the potential of

UVAMM to enhance efficiency.

The UVAMM helps to reduce feeding force (

), radial force (

), and axial force

(

) up to 7.6%, 11.5%, and 1.3%, respectively, and optimize surface quality and

burr suppression.

These composites showed excellent processing characteristics when subjected to

precise feed rate and ultrasonic amplitude conditions (1μm/tooth and 3.05μm, re‐

spectively). This shows the capacity to optimize UVAMM parameters to attain

higher outcomes for composite materials.

Findings offered proof of the ability of UVAMM to enhance surface integrity and

quality. Their study also investigated the impact of vibration frequency and ampli‐

tude on surface roughness and burr size. They discovered a positive correlation be‐

tween surface roughness and frequency, as well as a negative correlation between

surface roughness and amplitude.

Investigated the effects of vibration assistance on tool wear, cutting forces, surface

roughness, and burr formation. The results show the reduction in tool wear, cutting

forces, surface roughness and burr formation demonstrating the efficiency of

UVAMM.

The findings demonstrated that employing ultrasonic vibration resulted in a signifi‐

cant 17% and 12% reduction in cutting forces for titanium alloy TC4 and alumi‐

num alloy 6061T6, respectively, when compared to the CMM.

The experimental results show that horizontal ultrasonic vibrations can change the

morphology of the burr, transforming it from an elongated form to a continuous

sheet-like structure that results in an improvement in surface finish in micro

grooves.

In this investigation, UVAMM and CMM were compared, with a particular focus

on cutting forces, tool wear, surface morphology, and corrosion resistance. The re‐

sults show that UVAMM reduces cutting forces, leading to exceptional surface

quality. Furthermore, the application of ultrasonic vibration greatly improves the

surface corrosion resistance of Inconel 718.

The results demonstrated that UVAMM enhances chip breakdown, promotes the

development of burr cracks, and efficiently reduces burr formation.

Simulation and experimental results proved that applying high-frequency ultrason‐

ic vibration in the milling feed direction reduces cutting temperature and cutting

force, improves chip breaking ability, and reduces burr formation.

No. Authors Materials Vibration type Improvements compared with CMM

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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Zhang et al. 73

Xu et al. 115

Jin and Xie 137

Li et al. 84

Ding et al. 104

Shang et al. 61

Huan et al. 53

Yan et al. 40

Su et al. 79

Al6061 aluminum alloy

45# steel

BK-7 optical glass

Ti-6Al-4V titanium alloy

Tool steels of HRC 55

and HRC 58

Al6061 aluminum alloy

TiC Particle-Reinforced

Titanium Matrix Com‐

posites

TC4 titanium alloy

Researchers experimentally verified a dynamic cutting force model for micro-end

milling of Al6061. This model considers tool vibration and runout. Their model

demonstrated greater precision compared to conventional models and effectively

predicted and comprehended cutting forces in UVAMM processes.

The researchers conducted orthogonal experiments to investigate the impact of

grain size and ultrasonic vibration on cutting forces, dimensional accuracy, and sur‐

face roughness. Their findings showed that materials with larger grain sizes tend to

exhibit reduced cutting forces and attain improved surface quality when subjected

to same process parameters.

The researchers conducted a series of tests to investigate the impact of vibration di‐

rection, amplitude, and frequency on surface roughness and profile. Their findings

indicated that frequently utilized vibrations play an important role in enhancing the

quality of the surface, offering helpful insight for optimizing parameters of

UVAMM in the processing of optical glass.

The researchers conducted a comparative analysis of the effects of UVAMM and

CMM on both the structural integrity and quality of the parts. Their research aimed

to develop an efficient UVAMM system for cutting the bottom surface of micro‐

grooves.

Experiments that explored how vibration parameters affected surface roughness

and tool wear showed that using UVAMM can improve surface finish and lower

tool wear compared to CMM.

Researcher developed and experimentally verified a 2D UVAMM to predict the

cutting forces of Al6061. Their model accurately replicated cutting force curves

and provided valuable insights into the impact of vibration amplitude and frequen‐

cy on cutting forces.

The ABAQUS simulation software was used to study the changes in cutting force,

temperature, and processing conditions in the context of the CMM and UEVAMM

processes. Their study evaluated the resultant surface morphologies and particle

dispersion providing useful insights on the efficiency of UEVAMM on composites.

Researchers develop reliable predictive models of 3D machined surface morpholo‐

gy for the TC4 titanium alloy. The 3D surface morphology of the machined surface

under LUVAM was simulated, and LUVAM experiments were conducted to ex‐

plore the influence of processing parameters on surface morphology through simu‐

lation and experimentation. The results show that the simulation results are consis‐

tent with the experimental results, verifying the accuracy and reliability of the theo‐

retical model.

When compared to CMM, longitudinal-torsional ultrasonic-assisted and tangential

torsion-assisted ultrasonic spiral-assisted processing had the fewest burrs, the

smoothest surfaces, the largest fractal dimensions, and the least micro-milling

force.

Continued table 2

No. Authors Materials Vibration type Improvements compared with CMM

7. Research trends

Ultrasonic vibration-assisted micro-milling (UVAMM) is a de‐

veloping field of research with a focus on reducing cutting force,

improving tool life, improving surface quality, optimizing machin‐

ing efficiency, and expanding its capabilities to the manufacturing

industry. The research trend in UVAMM is focused on several key

areas:

(1) A major focus is on finding the optimal combination of ultra‐

sonic vibration parameters (amplitude, frequency) and conventional

cutting parameters (cutting speed, feed rate) for different materials.

This research often involves using simulations and experimental

verification to identify settings that minimize cutting forces, im‐

prove surface quality, and extend tool life.

(2) The research focus is also increasing to explore the impact of

combined vibrations of the tool and workpiece on the machining

performance to improve efficiency as compared to applying vibra‐

tions only to the tool or workpiece.

(3) Researchers are exploring the combination of ultrasonic vi‐

bration with other micro-milling techniques like cryogenic cooling

Journal of Advanced Manufacturing Science and Technology 5(2) (2025) 2025009

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or the use of specific cutting tool geometries to achieve even better

results. Cryogenic cooling, for instance, can further reduce heat

generation, potentially improving the machinability of heat-sensi‐

tive materials. It is exploring how ultrasonic vibration can be used

to reduce cutting forces and tool wear, ultimately leading to less en‐

ergy consumption and a lower overall environmental impact.

(4) A well-designed ultrasonic vibration-assisted device plays an

important role in improving efficiency. Therefore, the researchers

have focused on optimizing the design of the ultrasonic device to

achieve higher efficiency in UVAMM.

(5) The interest in using UVAMM for machining novel materials

that are difficult to process with conventional techniques is increas‐

ing. This includes research on the machining of composite materi‐

als, high-strength alloys, and even hard-to-cut biomaterials for med‐

ical applications.

(6) The research focuses on sustainable micro-milling due to

growing environmental concerns. It is exploring how ultrasonic vi‐

bration can be used to reduce cutting forces and tool wear, ultimate‐

ly leading to less energy consumption and a lower overall environ‐

mental impact.

Acknowledgment

This work was supported by the National Natural Science Foun‐

dation of China (Nos. 52375400 and 51975053), Independent Inno‐

vation and Special Funding Project (No. ZZCX-2023-029), Basic

Research Foundation of Beijing Institute of Technology (No.

2021CX01023).

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Vibration-assisted micro-milling has emerged as a promising technique in vibration-assisted machining, aiming to enhance machining quality by applying small-amplitude high-frequency vibrations to the workpiece during micro-milling operations. This paper presents a novel design of a piezo actuator-based non-resonant type workpiece vibratory system specifically designed for 2D vibration-assisted micro-milling application. The developed system is experimentally evaluated by generating 2D vibrations, considering each axis’ cross-coupling and hysteresis displacements, at various actuation frequencies ranging from 100 to 600 Hz. The application of the proposed setup focuses on the micro-milling of slots on an Aluminum 6061 and Titanium grade-5 workpiece samples, utilizing 2D sinusoidal out-of-phase vibrations along x and y directions with a peak-to-valley amplitude of 10 µm. The cutting force data is collected and recorded by a tool force dynamometer, and the root mean square value of the cutting force is used as a parameter to compare conventional micro-milling with vibration-assisted micro-milling processes. In addition, the study compares the average surface roughness of the milled slots when using vibration assistance and without it. The experimental results demonstrate a significant decrease in cutting force and an improvement in the average surface roughness of the milled slot when implementing 2D vibration-assisted micro-milling. These findings highlight the significance of the design, characterization, applicability, and suitability of the proposed non-resonant workpiece vibratory system in the field of vibration-assisted micro-milling process.

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Borosilicate glass has good light transmittance and stable chemical property, which is an ideal material for microfluidic chip matrix, However, brittle fracture is easy to occur during processing, which is a typical material difficult to process. This limits the surface accuracy. In recent years, longitudinal torsional ultrasonic vibration–assisted milling (LTUVAM) has been proposed as an effective way to machine hard and brittle materials. To elucidate the mechanism of material removal methods and elaborate the material removal mechanism during longitudinal torsional ultrasonic vibration–assisted milling process, this paper established a 3D morphology prediction model to investigate the material removal method. Firstly, the three-dimensional surface morphology model was created by describing the intricate tool path and the workpiece surface morphology reconstruction process under ultrasonic conditions while also considering the tool run-out effect. The model exhibited a certain degree of scalability, enabling the acquisition of various process morphology prediction models by altering the tool coordinates via matrix manipulation. Secondly, the accuracy of the model was verified by longitudinal torsional ultrasonic processing experiments. Thirdly, longitudinal torsional ultrasonic vibration–assisted milling experiments and longitudinal ultrasonic vibration–assisted milling experiments were conducted, and the surface roughness of the machined workpieces was measured. The experimental results show that LTUVAM further reduces the roughness compared with LUVAM, indicating that the reduction ratio reaches a maximum value of 61.06% at the spindle speed of 16,000 RPM, and then, the reduction ratio decreases to 42.88% with the increase of spindle speed. Combining modeling and experimental results, we concluded that LTUVAM was more advantageous in achieving plastic material removal and enhancing the surface quality of the machined surface compared to LUVAM. And under the same process conditions, as the spindle speed increases, the surface roughness of the workpiece increases first and then decreases.

Probabilistic model of the surface residual height under longitudinal-torsional ultrasonic vibration assisted micro-milling TC4

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Nov 2023
INT J ADV MANUF TECH

Longitudinal-torsional ultrasonic vibration assisted micro-milling (LUVAM) can significantly improve the machinability of TC4 titanium alloy. With the continuous improvement of machining accuracy of many micro parts in the special industry field, the surface formation mechanism of TC4 titanium alloy under LUVAM has gradually become a research hotspot, and it is necessary to develop a reliable prediction model of the three-dimensional (3D) surface morphology of the machined surface of TC4 titanium alloy. In the study, the surface formation mechanism of TC4 titanium alloy under LUVAM is explored by a probabilistic model. Firstly, the mechanism of the intermittent cutting characteristics of LUVAM is analyzed by the trajectories of the tool tip, and the instantaneous undeformed chip thickness (IUCT) of LUVAM is built to analyze the effect of ultrasonic vibration on the surface formation mechanism of TC4 titanium alloy under LUVAM. Secondly, the model of the comprehensive trajectories of the tool tip is established considering the radial runout of the cutter, the flexible deformation of the cutter and the elastic recovery of the machined surface, then a probabilistic model of the machined surface residual material height of TC4 titanium alloy under LUVAM is further established to predict the 3D surface morphology of the machined surface of TC4 titanium alloy under LUVAM. Finally, the 3D surface morphology of the machined surface of TC4 titanium alloy under LUVAM is simulated, and the experiments of LUVAM applied to TC4 titanium alloy were carried out to explore the influence of processing parameters on the surface morphology. The simulated and experimental results show the simulation results are consistent with the experimental results, which verifies the accuracy and reliability of the theoretical model. As a result, the probabilistic model of the residual surface material height of TC4 titanium alloy under LUVAM can provide the theoretical and technical reference for the surface formation mechanism of TC4 titanium alloy under LUVAM, which may further promote the development and application of TC4 titanium alloy in many micro-scale parts processing fields.

Research on ultrasonic vibration–assisted micro-EDM milling of microgrooves with large aspect ratio

Article

Full-text available

Jul 2023
INT J ADV MANUF TECH

For the purpose of improving the machining efficiency and quality of microgrooves with a large aspect ratio on titanium alloy, ultrasonic vibration–assisted micro-electrical discharge machining (micro-EDM) is employed. It can greatly reduce the occurrence of abnormal discharges and increase the valid discharge ratio during the processing so that large aspect ratio microgrooves can be obtained more efficiently. Based on the theory of the ultrasonic vibration system, this research carried out the selection of the ultrasonic generator, the design of the ultrasonic transducer, and the design of the ultrasonic horn. The amplitude and frequency tests of the ultrasonic vibration system had verified the effectiveness of the ultrasonic vibration system. Finally, on the foundation of the single factor experiment, the present research explored the influence of processing parameters (pulse width, pulse interval, peak current, and ultrasonic amplitude) on the material removal rate (MRR), relative tool wear rate (RTWR), and surface roughness (Ra) and proved the effectiveness of additional ultrasonic vibration in improving the machining efficiency and surface quality of microgrooves with a large aspect ratio on titanium alloy.

An overview of the machinability of alloy steel

Article

Full-text available

Mar 2023

Machinability is an important aspect for the machining of any materials. In general, it is controlled by means of tool life, surface roughness, power consumption, chip morphology, cutting forces, cutting fluid and material removal rate. Furthermore, it is also affected the microstructure, grain size, hardness, yield, tensile strength and chemical composition of the work piece material and tool materials. Advanced materials such as alloy steel, structural ceramics, and hardened steel are difficult to machine using conventional tool materials. The machining parameters such as depth of cut, cutting velocity and feed rate play a very important role to achieve high quality of surface finish on the machined surface. High interface temperatures at the tool tip and work piece material resulted poor surface finish and increases cutting forces and tool wear. A high cutting speeds with high feed and depth of cut causes high heat generation which reduces the tool substrates bonding strength resulting in accelerated tool wear and reducing tool life. In this article influence of heat treatment to enhance machinability alloy steel reviewed in terms of tool life, surface roughness, cutting forces and chip morphology. This article will be very useful for the students, research scholar and industrialist working in the area of machining.

Study on the Mechanism of Burr Formation by Simulation and Experiment in Ultrasonic Vibration-Assisted Micromilling

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Full-text available

Mar 2023

Due to the strong plasticity of Inconel 718 and the significant size effect of micromachining, a large number of burrs will be produced in traditional processing. The addition of ultrasonic vibration during machining can reduce the burr problem. The mechanism of burr generation in traditional micromilling (TMM) and ultrasonic vibration-assisted micromilling (UVAMM) was analyzed by simulation, and verified by corresponding experiments. It is found that applying high-frequency ultrasonic vibration in the milling feed direction can reduce cutting temperature and cutting force, improve chip breaking ability, and reduce burr formation. When the cutting thickness will reach the minimum cutting thickness hmin, the chip will start to form. When A/ƒz > 1/2, the tracks of the two tool heads start to cut, and the chips are not continuous. Some of the best burr suppression effects were achieved under conditions of low cutting speed (Vc), feed per tooth (ƒz), and large amplitude (A). When A is 6 μm, the size and quantity of burr is the smallest. When ƒz reaches 6 μm, large continuous burrs appear at the top of the groove. The experimental results further confirm the accuracy of the simulation results and provide parameter reference.

Ultrasonic vibration assisted milling of titanium alloy microchannel

Article

Feb 2024
PRECIS ENG

Towards understanding the cutting temperature in ultrasonic vibration-assisted drilling based on the dynamic contact characteristics between the cutting edge and workpiece

Article

Aug 2023
ULTRASONICS

Compared with conventional drilling (CD), ultrasonic vibration-assisted drilling(UVAD) is experimentally proven a promising method to reduce the cutting temperature. But sometimes cutting temperature also becomes higher in UVAD than in CD. To further make clear the cutting temperature mechanisms in UVAD, this study aims to study the effect of tool's ultrasonic vibration on the cutting heat generation and heat dissipation at a relatively micro level. Firstly, drilling experiments are designed to explore the variations of cutting heat under different ultrasonic vibrations. Then, to analyze the influence of ultrasonic vibration on the cutting heat theoretically, a kinematic model is developed to describe the dynamic contact between the cutting edge and workpiece in UVAD. Besides, a cutting heat analysis model based on the contact characteristics in UVAD is proposed to study and compare the variations of cutting heat generation. The effect of ultrasonic vibration on the cutting heat generation, heat dispassion, and the resultant cutting temperature under different machining in UVAD conditions are discussed. It is indicated from the theoretical analysis that more cutting heat tends to be produced due to the significantly increased sliding velocity on the cutting edge-workpiece interface when the ultrasonic vibration is applied. The analysis agrees with the experimental results that the cutting temperature in dry UVAD is higher than in dry CD. But on the other hand, ultrasonic vibration can also improve the lubrication and cooling effect under appropriate machining conditions, which is beneficial to the reduction in cutting temperature. The investigation shows the multifaceted influences of ultrasonic vibration on the cutting temperature in the drilling process in detail, which provides a reference for UVAD parameter optimization.

Research on Cutting Force of Vibration-assisted Micro-milling of Bone Materials

Conference Paper