Finite Element Analysis and Experimental Study of the Ultrasonic Vibration-assisted Single Point Incremental Forming (UVaSPIF) Process

Document Type: Research Paper

Author

Shahrood University of Technology

Abstract

The mechanism of Single Point Incremental Forming (SPIF) process is based on localized plastic deformation of a sheet metal using a hemispherical-head tool that follows the path programmed into the controller of a CNC milling machine. In this process, no die is used under the sheet metal for support. The researchers' findings show that by applying ultrasonic vibration in forming processes, metallic samples are subjected to plasticization transiently and considerably. The beneficial results of applying ultrasonic vibration in the forming processes are due to volume and surface effects that are related to the change in the properties of material and change of frictional conditions, respectively. In this article, the Ultrasonic Vibration-assisted Single Point Incremental Forming (UVaSPIF) process was simulated in finite element software. The results of numerical analysis showed that ultrasonic excitation of the forming tool and increasing of the vibration amplitude reduced the friction force and the vertical component of forming force. In the following, the results of the simulation process were compared with the experimental results at a frequency of 20 kHz and 7.5 μm vibration amplitude. The study of the results showed that there was a very good agreement between the values of the vertical component of the forming force resulting from the numerical analysis and the experimental test.

Keywords


[1]   Langenecker, B. “Work-softening of metal crystals by alternating the rate of glide strain”. Acta Metallurgica, 9 (1981) 937-940.

[2]   LangeneckerB., “Effects of ultrasound on deformation characteristics of metals”. IEEE Transactions on Sonics and Ultrasonics, 13 (1966) 1-8.

[3]   Bagherzadeh, S., Abrinia, K. “Effect of Ultrasonic Vibration on Compression Behavior and Microstructural Characteristics of Commercially Pure Aluminum”. Journal of Materials Engineering and Performance, 24 (11) (2015) 4364–4376.

[4]   Haiyang, Z., Hongzhi, C., Qing, H.Q. “Influence of ultrasonic vibration on the plasticity of metals during compression process”. Journal of Materials Processing Technology, 251 (2018) 146-159.

[5]   Blaha, F., Langenecker, B., “Tensile deformation of zinc crystal under ultrasonic vibration”. The Science of Nature, 42 (20) (1955) 556.

[6]   Huang, Z., Lucas, M., Adams, M.J., 2002. “Influence of ultrasonics on upsetting of a model paste”. Ultrasonics, 40 (2002) 43-48.

[7]   Li, L., Lang, X., “Wire drawing with ultrasonic vibration”. Journal Wire Industry, 61 (1994) 721.

[8]   Ashida, Y., Aoyama, H., 2007. “Press forming using ultrasonic vibration”. Journal of Materials Processing Technology, 187–188 (2007) 118–122.

[9]   AkbariMousavi, S.A.A., Feizi, H., Madoliat, R., “Investigations on the effects of ultrasonic vibrations in the extrusion process”. Journal of Materials Processing Technology, 187 (2007) 657-661.

[10]  Djavanroodi, F., Ahmadian, H., Koohkan, K., Naseri, R., “Ultrasonic-assisted ECAP”. Ultrasonics, 53 (2013) 1089-1096.

[11]  Ahmadi, F., Farzin, M., 2013. “Finite element analysis of ultrasonic-assisted equal channel angular pressing”. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 228 (11) (2013) 1859-1868.

[12]  Faraji, G., Ebrahimi, M., Bushroa, AR., “Ultrasonic assisted tubular channel angular pressing process”. Materials Science & Engineering: A, 599 (2014) 10-15.

[13]  Vahdati, M., Mahdavinejad, R.A., Amini, S., “Investigation of the ultrasonic vibration effect in incremental sheet metal forming process”. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 231 (6) (2015) 971-982.

[14]   Pengyang, L., Jin, H., Qiang, L., Mingshun, Y., Quandai, W., Qilong, Y., Yan, L., 2017. “Evaluation of forming forces in ultrasonic incremental sheet metal forming”. Aerospace Science and Technology, 63 (2017) 132–139.

[15]  Toshiyuki, O., Mamoru, H., 2017. “Ultrasonic-Assisted Incremental Microforming of Thin Shell Pyramids of Metallic Foil”. Micromachines, 8 (2017) 142, doi:10.3390/mi8050142.

[16]  Sakhtemanian, M.R., Honarpisheh, M., Amini, S. “A novel material modeling technique in the single-point incremental forming assisted by the ultrasonic vibration of low carbon steel/commercially pure titanium bimetal sheet”. International Journal of Advanced Manufacturing Technology, 102 (1-4) (2019) 473-486.

Dassault Systèmes, www.3DS.com/simulia (2002, accessed 2019).