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Purpose The purpose of this paper is to study the effect of ultrasonic machining process parameters on surface quality while machining titanium alloy Ti-6Al-4V. Design/methodology/approach Effect of cryogenic treatment (CT) of tool and work material was also explored in the study. Taguchi’s L18 orthogonal array was chosen for design of experiments and average surface roughness was measured. Findings Different modes of fracture were detected at work surface corresponding to varied input process parameters. Slurry grit size, power rating and tool material along with CT of work material were found to be the significant parameters affecting surface quality. Originality/value The results obtained have been modelled using artificial neural network approach.

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