Review on ultrasonic machining

Ultrasonic machining is of particular interest for the cutting of non-conductive, brittle workpiece materials such as engineering ceramics. Unlike other non-traditional processes such as laser beam, and electrical discharge machining, etc., ultrasonic machining does not thermally damage the workpiece or appear to introduce significant levels of residual stress, which is important for the survival of brittle materials in service. The fundamental principles of ultrasonic machining, the material removal mechanisms involved and the effect of operating parameters on material removal rate, tool wear rate and workpiece accuracy are reviewed, with particular emphasis on the machining of engineering ceramics. The problems of producing complex 3-D shapes in ceramics are outlined.