In ultrasonic-assisted machining, the synergistic effect of the cavitation effect and micro-abrasive particles plays a crucial role. Studies have focused on the investigation of the micro-abrasive particles, cavitation micro-jets, and cavitation shock waves either individually or in pairs. To investigate the synergy of shock waves and micro-jets generated by cavitation with micro-abrasive particles in ultrasonic-assisted machining, the continuous control equations of a cavitation bubble, shock wave, micro-jet, and micro-abrasive particle influenced by the dimensionless amount (R/R₀), a particle size-velocity–pressure model of the micro-abrasive particle was established. The effects of ultrasonic frequency, sound pressure amplitude, and changes in particle size on micro-abrasive particle velocity and pressure were numerically simulated. At an ultrasonic frequency of 20 kHz and ultrasonic sound pressure of 0.1125 MPa, a smooth spherical SiO₂ micro-abrasive particle (size = 5 µm) was obtained, with a maximum velocity of 190.3–209.4 m/s and pressure of 79.69–89.41 MPa. The results show that in the range of 5–50 μm, smaller particle sizes of the micro-abrasive particles led to greater velocity and pressure. The shock waves, micro-jets, and micro-abrasive particles were all positively affected by the dimensionless amount (R/R₀) of cavitation bubble collapse, the larger the dimensionless quantity, the faster their velocity and the higher their pressure.

In industrial production and scientific research, ultrasonic cavitation technology, with its outstanding physical and chemical processing capabilities, has been widely applied in fields such as material surface modification, chemical synthesis, and biotechnology, becoming a focal point of research and application. This article delves into the effects of different ultrasonic frequencies on cavitation outcomes through the combined use of numerical simulation, fluorescence analysis, and high-speed photography, specifically analyzing the quantitative improvement in the mechanical properties of TC17 titanium alloy under ultrasonic cavitation at frequencies of 20 kHz, 30 kHz, and 40 kHz. The study found that at an ultrasonic frequency of 20 kHz, the maximum expansion radius of cavitation bubbles can reach 51.4 μm, 8.6 times their initial radius. Correspondingly, fluorescence intensity and peak area also increased to 402.8 and 28104, significantly above the baseline level. Moreover, after modification by ultrasonic cavitation, the original machining marks on the surface of TC17 titanium alloy became fainter, with the emergence of new, uniformly distributed microfeatures. The microhardness of the material increased from 373.7 Hv to 383.84 Hv, 396.62 Hv, and 414.06 Hv, with a maximum improvement of 10.8 %. At the same time, surface height difference and roughness significantly decreased (to 3.168 μm and 0.61 μm respectively), with reductions reaching 45.1 % and 42.4 %, indicating a significant improvement in material surface quality. Notably, there is a negative correlation between the improvement of mechanical properties and ultrasonic frequency, suggesting that the improvement effects decrease as ultrasonic frequency increases. This research not only reveals the quantitative relationship between ultrasonic cavitation frequency and material surface modification effects but also provides a solid scientific basis and practical guidance for the application of ultrasonic cavitation technology in surface engineering, signifying the technology's potential for broad application in the future.

Cavitation will occur in the process of power ultrasonic honing. To explore the influence of cavitation on the material surface processed, an ultrasonic honing cavitation orthogonal experiment is conducted and three indicators are analyzed, which are pits’ maximum diameter, surface erosion rate, and surface roughness and can represent the single bubble collapse strength, the whole cavitation strength, and the impact of cavitation on material surface quality, respectively. The results show that cavitation leads to micro-pits on material surface. The main factors influencing the pits’ maximum diameter are distance and amplitude in turn; meanwhile, the shorter distance and the greater amplitude result in the larger pits’ maximum diameter. The surface erosion rate is mainly affected by experiment time and distance in order. Amplitude has the greatest influence on the surface roughness. The sample surface roughness reduces and surface quality improves in the condition of distance of 5 mm, amplitude of 65%, and experiment time of 1/3 min. Therefore, cavitation effect can help to enhance the workpiece surface quality in power ultrasonic honing under certain conditions, and the experimental analysis results have reference significance to the actual processing of ultrasonic honing.

In the field of power ultrasonic vibration processing, the thin liquid layer nestled between the tool head and the material serves as a hotbed for cavitation shock wave emissions that significantly affect the material's surface. The precise manipulation of these emissions presents a formidable challenge, stemming from a historical deficit in the quantitative analysis of both the ultrasonic enhancement effect and the shock wave intensity within this niche environment. Our study addresses this gap by innovatively modifying the Gilmore-Akulichev equation, laying the groundwork for a sophisticated bubble dynamics model and a pioneering shock wave propagation model tailored to the thin liquid layer domain. Firstly, our study investigated the ultrasound enhancement effect under various parameters of thin liquid layers, revealing an amplification of ultrasound pressure in the thin liquid layer area by up to 7.47 times. The mathematical model was solved using the sixth-order Runge–Kutta method to examine shock wave velocity and pressure under different conditions. our study identified that geometric parameters of the tool head, thin liquid layer thickness, ultrasonic frequency, and initial bubble radius all significantly influenced shock wave emission. At an ultrasonic frequency of 60 kHz, the shock wave pressure at the measurement point exhibited a brief decrease from 182.6 to 179.5 MPa during an increase. Furthermore, rapid attenuation of the shock wave was found within the range of R₀-3R₀ from the bubble wall. This research model aims to enhance power ultrasonic vibration processing technology, and provide theoretical support for applications in related fields.