Industries have been pursuing a competent machining strategy that fulfills the necessity of sustainability without deteriorating tool wear or final product quality of components made from difficult-to-cut material Titanium 64. This article attempts a combination ultrasonic vibration with vegetable oil-based cutting fluid (VCF), to increases the tool life and machinability of Titanium 64. In-house developed Ultrasonic-assisted turning (UAT) setup for vibration, and emulsion of 10% Canola oil for cooling, are used. The machinability in respect of cutting and feed force, tool-chip contact length, and flank and crater wear, are examined. As a result, the UAT under VCF offers a reduction in tool-chip contact length by 12–45%, cutting force by 10–25%, and feed force by 20–40%. Moreover, ultrasonic-assisted turning using vegetable oil-based cutting fluid also decreases the adhesion and abrasion wear from the rake face, which is obvious in the conventional turning process of Titanium 64.

Nickel-based superalloys are widely used in the aerospace, automotive, marine and medical sectors, owing to their high mechanical strength and corrosion resistance. However, they exhibit poor machinability due to low thermal conductivity, high shear modulus, strain hardening, etc. Various modifications have been incorporated into existing machining techniques to address these issues. One such modification is the incorporation of ultrasonic assistance to turning operations. The assisted process is popularly known as ultrasonic assisted turning (UAT), and uses ultrasonic vibration to the processing zone to cut the material. The present article investigates the effect of ultrasonic vibration on coated carbide tool wear for machining Nimonic-90 under dry and wet conditions. UAT and conventional turning (CT) were performed at constant cutting speed, feed rate and depth of cut. The results show that the main wear mechanisms were abrasion, chipping, notch wear and adhesion of the built-up edge in both processes. However, by using a coolant, the formation of the built-up edge was reduced. CT and UAT under dry conditions showed an approximate reduction of 20% in the width of flank wear compared to CT and UAT under wet conditions. UAT showed approximate reductions of 6–20% in cutting force and 13–27% in feed force compared to the CT process. The chips formed during UAT were thinner, smoother and shorter than those formed during CT.

Reverse micro electro-discharge machining (RµEDM) is a promising and cost-effective technology for fabricating unconventional shaped single and arrayed micro-pins of high aspect ratio. However, dimensional inaccuracies, poor surface finish and long machining time are of great concern. An experiment-based detailed investigation of process parameters for analyzing various machining responses has been performed in this article. Taguchi’s L16 orthogonal array design of experiments has been used to frame out the experimental runs. Discharge voltage, capacitance and feed rate have been considered as process parameters whereas, material removal rate, taper root angle, surface roughness and machining time as responses for the fabrication of a single micro-pin. Additionally, the feasibility of a novel high-pressure suction flushing technology implemented for RµEDM has been demonstrated. The performance of this technology is verified for better surface quality and lesser machining time. It is observed that by using the proposed suction technology, along with the suitable parametric settings, the micromachining time significantly improved (~20%) while fabricating an arrayed micro-pins in elliptical cross-sections profile.