Ultrasonic Process Research Articles

Gradient residual stress evolution and its influence on fatigue life under combined carburising heat treatment and ultrasonic surface rolling process

This study combined carburising heat treatment (CHT) with the ultrasonic surface rolling process (USRP) to improve the rotary bending fatigue properties of 18CrNiMo7-6 alloy steel. Based on the experimentally obtained fatigue limit (σ-1), the evolution of gradient compressive residual stress (CRS) of CHT- and CHT + USRP-treated specimens was analysed below the fatigue limit stress level. Subsequently, the evolution mechanism of gradient CRS of the two reinforced specimens was discussed and analysed from the opposing effects of austenite transformation and dislocation density change on the evolution of CRS. The results demonstrated that the selective bending fatigue performance of the alloy was evidently improved after the introduction of CRS; however, the change in fatigue limit was not evident. The durability under other loads (such as cyclic tension/compression and torsion loads) needs further study. The gradient CRS evolution of CHT specimens was mainly caused by the large residual austenite transformation and small dislocation density change. Therefore, the volume expansion caused by residual austenite transformation gradually increased the gradient compression residual stress of CHT specimens with an increased number of cycles. Contrarily, the degree residual stress evolution of CHT + USRP specimens was more affected by the dislocation density, and the gradient compression residual stress gradually decreased with an increased number of cycles. Finally, the residual stress evolution rate of the two reinforced specimens was divided into two stages: fast and slow.

High-Performance Flexible Hybrid Silica Membranes with an Ultrasonic Atomization-Assisted Spray-Coated Active Layer on Polymer for Isopropanol Dehydration.

Organic-inorganic hybrid silica materials, incorporating an organic group bridging two silicon atoms, have demonstrated great potential in creating membranes with excellent permselectivity. Yet, the large-scale production of polymer-supported flexible hybrid silica membranes has remained a significant challenge. In this study, we present an easy and scalable approach for fabricating these membranes. By employing a sol-gel ultrasonic spray process with a single-pass method, we deposited a thin and uniform hybrid active layer onto a porous polymer substrate. We first optimized the deposition conditions, including substrate temperature, the binary solvent ratio of the silica sol, and various ultrasonic spray parameters. The resulting flexible hybrid silica membranes exhibited exceptional dehydration performance for isopropanol (IPA)/water solutions (IPA: 90 wt%) in the pervaporation process, achieving a water flux of 0.6 kg/(m2 h) and a separation factor of around 1300. This work demonstrates that the single-pass ultrasonic spray method is an effective strategy for the large-scale production of polymer-supported flexible hybrid silica membranes.

Tribological and mechanical properties improvement of G20CrNiMo alloy via fabricating gradient composite layer through ultrasonic strengthening grinding process

Fretting wear is one of the main causes of damage failure at the contact interface, which significantly limits the reliable application of mechanical parts. To address this issue, a composite microstructure comprising a gradient structure, α-Al2O3 particles, and micro-dimples was fabricated on the G20CrNiMo alloy by an improved method of ultrasonic strengthening grinding process (USGP). Subsequently, the fretting resistance and mechanical properties of the treated G20CrNiMo alloy were investigated. The results indicated that USGP could significantly enhance mechanical strength and wear resistance properties. The USGP-treated sample demonstrated an increment of approximately 25.32 % in tensile strength compared to the untreated sample. It also exhibited reductions of about 19.61 % and 49.56 % in friction coefficient and wear volume, respectively. After USGP treatment, the gradient structure incorporating dense dislocation and high-angle grain boundaries (HAGBs) limited the shear motion of the G20CrNiMo alloy, thereby enhancing its mechanical properties. Furthermore, the synergistic effect of gradient structure, Al2O3 particles, and micro-dimples effectively restricted shear deformation and formed a supplementary glaze to further improve its fretting wear resistance.

Experimental investigation on surface integrity and fatigue performance of Ti60 alloy under ultrasonic impact treatment

The surface integrity and fatigue properties of Ti60 alloy under different ultrasonic impact processes were investigated. Ultrasonic impact treatment (UIT) with various parameters enhanced the surface integrity of the turned specimen. The Ra values of the UIT specimens were all less than 0.380 μm, with the surface stress concentration factor (Kst) values ranging from 1.075 to 1.120. The compressive residual stress values of the UIT specimens were enhanced, leading to the localization of the maximum residual stress (σrsm) in the subsurface. Increases in surface residual stress (σs) values exceeded 21.9 % and σrsm values were improved by more than 74.4 % compared to the turned specimen. The microhardness values showed improvement after UIT, with surface microhardness (HVs) values ranging from 408.5 HV0.025 to 461.6 HV0.025. The orientation of the grains was deflected in UIT specimens, and the depths of the plastic deformation layer (hp) values experienced increases of more than 17 times. The fatigue life (Nf) value of the Comb. U2 with the best surface integrity was approximately 9328.4 % higher than that of turned and about 4362.1 % higher than that of Comb. U1 with the worst surface integrity among the UIT specimens. Observing the fatigue fractures, the crack initiation locations of the UIT specimens were relocated to the subsurface at a distance of more than 150 μm from the surface. A higher fatigue life of the specimen was achieved when there was better surface integrity and when the fatigue crack source was located further away from the surface. The crack source in the UIT specimen exhibited a large and irregular shape, and there were numerous small, evenly distributed dimples and a limited number of cleavage planes in fatigue instantaneous fracture region. Additionally, it was found that the subsurface fatigue life prediction model demonstrates superior accuracy for shorter fatigue life.

Fabrication of NiO-CuO/RGO Composite for Lithium Storage Property

The lithium storage performance of binary transition metal oxide/graphene composites as anode materials has been attracting more interest from researchers, based on the fact that binary transition metal oxides and graphene are expected to create a synergistic effect and exhibit improved lithium storage characteristics. In this work, a NiO-CuO/reduced graphene oxide composite (NiO-CuO/RGO) was prepared by an ultrasonic agitation process. When the NiO-CuO/RGO is applied to the anode material for lithium-ion batteries (LIBs), the batteries display high discharge capacities (at 730 mA h/g after 100 cycles at 100 mA/g), high-rate performance (311 mA h/g with 5000 mA/g), and excellent stable cyclability (375 mA h/g within 2000 mA/g after 400 cycles). Such results indicate that the combination of NiO-CuO and RGO leads to enhanced lithium storage performance, for the RGO sheets inhibit the large volume change of binary NiO-CuO and enhance the fast transport of both lithium ions and electrons during the repeated lithium cycling processes.

Removal of pesticide residues from vegetables by hydrogen peroxide assisted ultrasonic process

This study addresses the concern of pesticide residues in vegetables by exploring the hydrogen peroxide assisted ultrasonic (H2O2/US) process for the removal of six pesticides from pakchoi, a popular green vegetable in China. Remarkably high efficiency was achieved, with removal rates reaching 83.9%, 68.8%, 85.9%, 91.6%, 75.6%, and 73.4% for dimethoate, dichlorvos, methiocarb, propoxur, chlorobenzuron, and etridiazole, respectively, through the H2O2/US process. A notable synergy was observed in the coupled H2O2/US process. The analysis of mass balance and degradation pathways indicates that the synergy stemmed from the efficient oxidation of pesticides by hydroxyl radicals (HO•) formed via sonolysis of H2O2. Surface properties of vegetables showed great impacts on pesticide removal by H2O2/US. Despite these treatments, the H2O2/US process exhibited minimal impact on vegetable quality. Overall, this study underscores the potential of the H2O2/US process as a promising technology for effectively removing pesticides from vegetables.

Ultrasonic-assisted preparation of SBS modified asphalt: Cavitation bubble numerical simulation and rheological properties

SBS (styrene–butadiene–styrene block copolymer) is currently the most widely used asphalt modifier, and SBS modified asphalt is usually prepared by high-speed shearing. This paper combines the cavitation effect of ultrasonic to assist in the preparation of SBS modified asphalt, and conducts numerical simulation and rheological properties research on the cavitation bubbles in the molten SBS modified asphalt fluid. The cavitation bubbles in the modified asphalt fluid will expand and contract as the pressure changes inside and outside the bubbles. When the cavitation bubble is compressed to the minimum and the pressure inside the bubble reaches 1.94 × 105Pa, the direction of the velocity vector near the cavitation bubble will change with the expansion and compression of the bubble. The expansion–contraction process of a single cavitation bubble can release 6.41 × 10-7J of energy, thus breaking the long bonds in asphalt and generating a large number of free radicals react with the unsaturated C = C bonds in the SBS molecules. According to the preparation process of modified asphalt, the influence of ultrasonic wave on rheological property of modified asphalt was studied through experiments. The results show that ultrasonic treatment can enhance the elasticity of asphalt and improve the temperature sensitivity of asphalt. With the increase of ultrasonic treatment time, the anti-rutting deformation ability of SBS modified asphalt is greatly improved. At the same temperature, the recovery rate of asphalt also increases with the increase of ultrasonic treatment time, and the non-recoverable compliance (Jnr) decreases Combined with the numerical simulation of cavitation bubbles, the ultrasonic process is added to asphalt production, which is of great significance for the green production of modified asphalt and the improvement of the rheological properties of modified asphalt.

Effect of different processing steps in the production of beer fish on volatile flavor profile and their precursors determined by HS-GC-IMS, HPLC, E-nose, and E-tongue

Beer fish is characterized by its distinctive spicy flavor and strong beer aroma. Currently, there is a lack of comprehensive research analyzing the changes in taste and volatile compounds that occur during the processing of beer fish. Thus, this study used HS-GC-IMS, electronic tongue, and electronic nose to investigate the changes in flavor components during various processing stages of beer fish. The obtained results were subsequently analyzed using multivariate statistical analysis. The results showed that the final beer fish product (SF) had the greatest amount of free amino acids (888.28 mg/100 g), with alanine, glutamic acid, and glycine contributing to the taste of SF. The inosine monophosphate (IMP) content of beer fish meat varied noticeably depending on processing stages, with deep-fried fish (FF) having the greatest IMP content (61.93 mg/100 g), followed by the final product (SF) and ultrasonic-cured fish (UF). A total of 67 volatiles were detected by GC-IMS, mainly consisting of aldehydes, ketones, and alcohols, of which aldehydes accounted for >37%, which had a great influence on the volatile flavor of beer fish. The flavor components' composition varied noticeably depending on the stage of processing. PLS-DA model screened 35 volatile flavor components (VIP > 1) as markers; the most significant differences were 1-propanethiol, isoamyl alcohol, ethanol, and eucalyptol. Ultrasonic processing, frying, and soaking sauce can significantly improve the formation of flavor compounds, resulting in a notable enhancement of the final beer fish's umami taste and overall flavor quality.

Green Sonochemical Synthesis of rGO Nanosheets‐Decorated by SnO2 Nanoparticles for Nitrogen Gas‐Sensing Applications

In recent years, the development of efficient and environmentally friendly synthesis methods for nanomaterials has gained significant attention in various research fields, particularly in gas‐sensing applications. Among these methods, ultrasonic synthesis stands out for its simplicity, cost‐effectiveness, and ecofriendly nature. Herein, a simple and green ultrasonic synthesis process is used to synthesize the SnO2 nanoparticles‐decorated rGO nanosheets. The obtained X‐ray diffraction reveals the tetragonal rutile‐type crystal structure. The transmission electron microscopy images reveal the decoration of SnO2 nanoparticles on the surfaces of the rGO sheets. SnO2 nanoparticles of size 4–8 nm are identified on the surfaces of the rGO sheets. Furthermore, the optical absorbance and photoluminescence spectra of the nanocomposites validate charge migrations occurring at the interface of SnO2 and the rGO sheets. Compared to the pristine SnO2 nanoparticles, the green ultrasonically synthesized SnO2 nanoparticles‐decorated SnO2/rGO nanocomposite exhibits better sensing performance against NO2 gas and shows selectivity for NO2 gas at 200 °C. The SnO2/rGO nanocomposite demonstrates high NO2 sensing with appealing sensing properties such as excellent responsiveness (67% at 400 °C), rapid reaction time (18 s), and short recovery time (25 s).

Эффективность комбинированного воздействия ультразвука и микроволн при обработке пищевых продуктов. Обзор

Modern methods of food processing combine ultrasonic and microwave treatment. This article reviews scientific publications on combined microwave and ultrasound technologies in food processing. The review involved standard methods of data analysis and covered 85 Scopus and Web of Science research papers on combined microwave and ultrasonic food treatment published in English in 2010–2023. The article describes the principles and specific features of ultrasonic and microwave food processing methods, their combinations, equipment design, and applications as part of various food processing stages, e.g., defrosting, drying, extraction, sterilization, etc. Microwaves increase the heating rate while ultrasound increases the efficiency of heat and mass transfer. Their combined use reduces processing time, improves product quality, facilitates moisture drainage, and provides uniform heating. The combined effect of microwaves and ultrasound increases the processing efficiency, thus preserving the nutritional value and quality of the final product. Ultrasonic technology serves as an aid to efficient and environmentally-friendly microwave heating, which has a wide range of applications in the food industry. The review can be used in further research in extraction, drying, defrosting, and sterilization. It can help food industry specialists to select optimal food processing methods.

Effects of Different Pretreatments on the GABA Content of Germinated Brown Rice

Brown rice germination increases γ-aminobutyric acid (GABA) levels and enhances its antioxidant activity. In this study, Kaohsiung 145 brown rice was used as the raw material, and soaked in various solutions for 6 h before being processed with either high-pressure processing (HPP) or ultrasonic treatment to increase the GABA content. The GABA and antioxidant components of brown rice were analyzed after 42 h of germination and subsequent air-drying to obtain a moisture content of 14%. The results showed that non-germinated brown rice had GABA at 7.10 mg/100 g and treatment with various soaking solutions (0.1% CaCl2, 0.1% Glu, 0.2% CaCl2, and 0.2% Glu) increased GABA contents. Specifically, 0.1% CaCl2 and 0.1% Glu exhibited higher GABA content, at 42.51 and 44.64 mg/100 g. Furthermore, the GABA content increased synergistically when combined with HPP (100 MPa, 10 min) and ultrasonic (20 min) treatments after soaking. The results showed that the GABA contents in germinated rice were the greatest after ultrasonic treatment, followed by HPP treatment, and the least with only soaking treatment. The treatments with 0.1% CaCl2 and 0.2% Glu combined with ultrasonic processing for 20 min resulted in the highest GABA content at 102.38 and 110.88 mg/100 g, respectively. Finally, 0.1% CaCl2 with ultrasonic treatment for 20 min was chosen, as it demonstrated a considerable improvement in total polyphenols content and DPPH scavenging abilities, as seen by improved scores in subsequent taste evaluations.

Microstructure evolution and surface strengthening behavior of 300 M ultrahigh strength steel under engineered surface treatments

In this work, the most efficient and common engineered surface treatments identified as shot peening (SP), laser shock peening (LSP) and ultrasonic surface rolling process (USRP) were utilized to impact the 300 M ultrahigh strength steel. The microstructure evolution and surface strengthening behavior were carefully characterized and compared for the 300 M steel with various treatments. Besides, the underlying mechanisms for difference in grain refinement and surface mechanical properties by the arranged surface modification are revealed. The results indicate that a gradient structure with nano-grains at the top surface appears on the SP, LSP and USRP treated samples. The process of repeated impacts of SP in different directions leads to activation of multiple slip systems, which thus causes severe refined grains and dense dislocation activities associated with dislocation tangles, dislocation walls and blocking. A great variety of strikes per unit area by USRP results in higher plastic deformation compared to SP where numerous dislocation cells and deformation bands were generated. In contrast to SP and USRP, fewer slip systems are activated in LSP due to the short duration time which thus leads to the thinnest refined grain layer and more planar dislocation structures. The combination of low plastic work and lack of refined grains leads to lowest full width at half maximum (FWHM) in case of LSP samples whereas high FWHM comes from both fine grain size and dislocations in SP. The grain refinement and plastic work contributes to an increase of microhardness and compressive residual stress for the SP, LSP and USRP samples. To be clear, SP leads to a higher magnitude of hardness and compressive residual stress on the topmost surface while LSP causes a larger depth due to that shock wave in LSP influences material to much greater depth. Besides, the decomposition and redistribution of carbides are also noticed on the surface layer after the surface treatments with very high strain rate where numerous dislocations accumulate at the border of the carbides and slip trace is also observed within the carbides.

High-flux ultrasonic processing for lithium separation using ionic liquid impregnated composite membranes

Battery industry, one of the most crucial components of the modern world, relies heavily on lithium production, and brines from the spent battery materials is one of the most important sources to exploit lithium. A new ultrasonic assisted membrane processing is proposed for lithium separation simulated brine. The effects of membrane composition, feed concentration, and ultrasonic conditions on the lithium extraction efficiency have been explored. The composite membrane including polysulfone (PSF) as the support and 1-alkyl-3-methylimidazolium hexafluorophosphate and tributyl phosphate as ionic liquid membrane. A porous PVC membrane has been used for prevention of the ILM loss. The optimal ultrasonic frequency is approximately 250 kHz, which matches the bulk modulus of the membrane and enhances the separation efficiency. Higher frequencies and optimized amplitude and pulse cycle settings further improve the lithium flux and selectivity. Moreover, higher flux and selectivity are achieved when separating lithium from alkali metal chlorides at higher feed concentrations, ranging from 250 ppm to 1000 ppm. The mechanism of enhanced lithium extraction by ultrasonics is attributed to the combination of microbubble formation, cavitation, and heat generation, which disrupt the concentration gradient and facilitate lithium transport across the membrane.

Enhanced strength-plasticity synergy of 304 stainless steel by introducing gradient nanograined single austenite phase structure via USRP and induction annealing

The drawback of low strength of 304 stainless steel could be overcome by fabricating gradient nanostructures (GNS). However, deformation-induced martensite results in magnetic generation and plasticity degradation. In this work, a single austenitic GNS 304 stainless steel is fabricated by first creating a dual-phase GNS through the ultrasonic surface rolling process (USRP), followed by rapid induction heating. The yield strength of the single austenite GNS (520 MPa) is 1.68 times higher than that of the homogeneous coarse-grained structure (310 MP) without sacrificing plasticity (elongation of 65 %). Quantitative calculations indicate that fine grain, dislocation, twinning, and back-stress strengthening contribute to the strength increment by 30 %, 17.5 %, 23.4 %, and 29.1 %, respectively. Coarse-grained regions deform mainly through FCC-HCP-BCC martensitic transformation, whereas the subsurface layer forms stacking faults and twins due to increased stacking fault energy caused by the reduction in grain size. At the topmost layer, the stress required to activate dislocations is lower than that for twinning. Under high-stress conditions, martensite forms along the nanograin boundaries via a phase transition from FCC to BCC. Consequently, the excellent plasticity of the single austenite GNS stems from the synergistic effects of high back-stress hardening, TRIP and TWIP effect.

The process of sonocatalytic degradation via γ-Fe2O3 to eliminate the antibiotic Co-Amoxiclav/ the effect of diverse parameters/ kinetics study/ using response surface methodology

In this work, the elimination of co-amoxiclav antibiotic from the water environment was optimized via the ultrasonic process coupled with γ Fe2O3 nanoparticles through the response surface methodology (RSM). In a laboratory investigation, parameters such as pH value (3–10), nanoparticle dose (0.1–0.3) g/L, reaction time (15–90) min, initial antibiotic concentration (20–75) mg/L and the frequencies of ultrasound waves (35–130) kHz were studied to assess the effect. The chemical oxygen demand (COD) was determined to track the elimination of Co-amoxiclav. The consequences of the data analysis showed that the catalyst dose and time contact had the greatest influence on the elimination rate of Co-Amoxiclav. The optimum condition in the performed runs were pH 3, ultrasound wave frequency 37 kHz, initial antibiotic concentration 10 mg/L, catalyst dose 0.2 g/L and reaction time 90 min. A COD removal efficiency of 97.09 was obtained with Co-Amoxiclav. The outcomes of this study illustrate that sonocatalytic elimination method has a high efficiency in eliminating Co-amoxiclav antibiotics from aqueous media.

Pb(II) Adsorption Properties of a Three-Dimensional Porous Bacterial Cellulose/Graphene Oxide Composite Hydrogel Subjected to Ultrasonic Treatment.

A three-dimensional porous bacterial cellulose/graphene oxide (BC/GO) composite hydrogel (BC/GO) was synthesized with multi-layer graphene oxide (GO) as the modifier and bacterial cellulose as the skeleton via an ultrasonic shaking process to absorb lead ions effectively. The characteristics of BC/GO were investigated through TEM, SEM, FT-IR, NMR and Zeta potential experiments. Compared to bacterial cellulose, the ultrasonic method and the carboxyl groups stemming from GO helped to enhance the availability of O(3)H of BC, in addition to the looser three-dimensional structure and enriched oxygen-containing groups, leading to a significantly higher adsorption capacity for Pb(II). In this paper, the adsorption behavior of BC/GO is influenced by the GO concentration, adsorption time, and initial concentration. The highest adsorption capacity for Pb(II) on BC/GO found in this study was 224.5 mg/g. The findings implied that the pseudo-second-order model explained the BC/GO adsorption dynamics and that the data of its adsorption isotherm fit the Freundlich model. Because of the looser three-dimensional structure, the complexation of carboxyl groups, and the enhanced availability of O(3)H, bacterial cellulose exhibited a much better adsorption capacity.

X-ray peak broadening analysis of Bougainvillea glabra assisted ultrasonic exfoliation of h-BN sheets

In this study, h-Boron Nitride (h-BN) nanosheets have been successfully exfoliated using Bougainvillea flower extract and ultrasonication process. The microstructural parameters such as microstrain, stress, and energy density were calculated using Williamson–Hall analysis. The time of ultrasonication and post-annealing temperature significantly alter the microstructure parameters such as crystal size, microstrain, stress, and energy density upon sonication. The lattice constants such as a-axis and c-axis, cell volume, and bond length did not alter significantly which confirms that there is no crystal structure deformation upon sonication and annealing processes. FESEM result revealed that exfoliation of h-BN and ultrasonication duration greatly influenced the exfoliation. Raman and FTIR studies confirm the pure phase of h-BN without secondary impurities. A simple ultrasonication process would effectively exfoliate h-BN layers and this could be used for tribological applications to reduce the friction between rubbing surfaces.

Online monitoring for extraction of Tibetan medicine Meconopsis quintuplinervia regel. Based on near infrared spectroscopy coupled with chemometrics

The extraction process plays a crucial role in the production of Tibetan medicines. This study focused on assembling a set of online near-infrared (NIR) spectroscopy detection devices for the extraction of medicinal herbs. The original infrared device was transformed into an online detection system. After evaluating the stability of the system, we applied online NIR spectroscopy monitoring to the flavonoid contents (total flavonoids, quercetin-3-O-sophoroside, and luteolin) of Meconopsis quintuplinervia Regel. during the ultrasonic extraction process and determined the extraction endpoint. Nine batches of samples were employed to construct quantitative and discriminant models, half of the remaining two batches of samples are used for external verification. Our research shows that the residual predictive deviation (RPD) values of total flavonoids, quercetin-3-O-sophoroside and luteolin models exceeded 2.5. The R values for external verification of the three ingredients were above 0.9, with RPD values generally exceeding 2 and RSEP values within 10 %, demonstrating the model’s strong predictive performance. Most of the extraction endpoints of the flavonoid components in M. quintuplinervia ranged from 18 to 58 min, with high consistency between the predicted extraction endpoints of the external validation, suggesting accurate determination of extraction endpoints based on predicted values. This study can provide a reference for the online NIR spectroscopy quality monitoring of the extraction process of Chinese and Tibetan herbs.

Room-Temperature Sensing Mechanism of GQDs/BiSbO4 Nanorod Clusters: Experimental and Density Functional Theory Study.

Creating high-performance gas sensors for heptanal detection at room temperature demands the development of sensing materials that incorporate distinct spatial configurations, functional components, and active surfaces. In this study, we employed a straightforward method combining hydrothermal strategy with ultrasonic processing to produce mesoporous graphene quantum dots/bismuth antimonate (GQDs/BiSbO4) with nanorod cluster forms. The BiSbO4 was incorporated with appropriate contents of GQDs resulting in significantly improved attributes such as heightened sensitivity (59.6@30 ppm), a lower threshold for detection (356 ppb), and quicker period for response (40 s). A synergistic mechanism that leverages the inherent advantages of BiSbO4 was proposed, while its distinctive mesoporous hollow cubic structure, the presence of oxygen vacancies, and the catalytic enhancement provided by GQDs lead to a marked improvement in heptanal detection. This work introduces a straightforward and effective method for crafting sophisticated micro-nanostructures that optimize spatial design, functionality, and active mesoporous surfaces, showing great promise for heptanal sensing applications.

Evaluation of tool wear during micro-milling of ultrasonically assisted abrasive peened Ti-6Al-4V

When a cutting tool shears through a workpiece, the interaction causes wear of the tool which is based on relative hardness, surface characteristics of the tool and the workpiece, cutting environment and thermal behaviour at the work/tool interface. In this study, wear of a micro-end milling tool is investigated while milling of as-received and peened work material (in this case, Ti-6Al-4V). The peening is performed with the help of an in-house developed ultrasonic cavitation process. The process excites the abrasives suspended in the cavitating medium, which impart on the work surface and induce compressive residual stress and uniform grain refinement. As the cutting process advances, a built-up is formed more rapidly in the as-received workpiece, leading to higher cutting forces and earlier chipping of the cutting edge. Under the peened conditions, it is found that the increase in tool edge radius and flank wear width reduce by 50 % and 54 % respectively compared to the as-received one. Additionally, peening-induced grain refinement leads to a 26 % decrease in surface roughness of the machined surface and inhibits burr formation by 60 %. A tool wear chipping model is employed to predict the tool diameter, cutting edge radius and flank wear width of the worn tool. Results show that the magnitude of flank wear, edge radius of worn tool and tool diameter deviate from experiments by 15.2 %, 14 % and 13 % respectively.