Performance of Ultrasonic-assisted Turning of Additively Manufactured Titanium Alloys

• • Under dry cutting at a feed rate of 0.05 mm/r, 2D UVAT reduces the main cutting force by 25.50% relative to conventional turning, directly lowering spindle power demand and enabling higher material removal rates without sacrificing tool life—critical for cost-sensitive aerospace component finishing. • • In wet cutting, 2D UVAT achieves a maximum main cutting force reduction of 22.73% versus conventional turning, though absolute forces remain higher than in dry cutting due to thermal softening effects; this challenges the assumption that flood cooling universally improves machinability in titanium alloys. • • Surface roughness (Ra) is reduced by 21.28%–37.11% under dry conditions and 14.68%–38.63% under wet conditions with 2D UVAT, directly addressing the as-built surface deficiency of AM titanium parts and potentially eliminating secondary polishing operations in medical implant manufacturing. • • 2D UVAT consistently yields higher average surface hardness and significantly less tool rake face adhesion compared to conventional turning, extending tool life and reducing unplanned downtime—an economic advantage in high-volume production where tooling costs constitute a substantial fraction of per-part expense.