Combining ultrasonic vibration (UV) with metal forming processes is investigated as a novel technology that has been able to reduce the forming force and enhance this process. This paper attempts to elucidate the effect of Ultrasonically Assisted Deep Drawing (UADD) process on the forming force and thickness distribution of the formed sample. Therefore, a Finite Element (FE) model is developed to simulate this process and further investigate the ultrasonic micro-hammer mechanism in UADD process. Experimental tests were conducted to validate the established numerical model. Accordingly, a robust technological equipment was designed and fabricated, so that by application of ultrasonic vibration, the drawing die will be stimulated in longitudinal mode at the frequency of 20 kHz and thus, remain in the resonant condition. A reasonable congruence was observed when the forming force results and cup configurations from experimental tests and numerical solutions were compared. Therefore, the numerical model was used to evaluate the deformation behavior of the sheet at different amplitudes and frequencies. The results confirmed continuous vibration and ultrasonic micro-hammer conditions exhibit different behavior during the UADD process, and the latter occurs when the ultrasonic die separates from the workpiece surface. Although the UV application under micro-hammer condition significantly reduces the forming force, it has a destructive effect on the thickness distribution of the sheet and causes severe thinning. The current study provides a better understanding of the ultrasonic micro-hammer and its effects on the sheet metal forming process, which is the fundamental step in exploring this process.

将超声波振动 (UV) 与金属成型工艺相结合作为一种新技术进行了研究，该技术能够降低成型力并增强该工艺。本文试图阐明超声辅助深拉（UADD）工艺对成形样品的成形力和厚度分布的影响。因此，开发了有限元（FE）模型来模拟该过程并进一步研究UADD过程中的超声微锤机制。进行了实验测试以验证所建立的数值模型。因此，设计和制造了一个强大的技术设备，以便通过施加超声波振动，拉丝模将在 20 kHz 的频率下以纵向模式受激，从而保持共振状态。当比较实验测试和数值解的成形力结果和杯配置时，观察到合理的一致性。因此，数值模型用于评估板材在不同振幅和频率下的变形行为。结果证实连续振动和超声波微锤条件在 UADD 过程中表现出不同的行为，后者发生在超声波模具与工件表面分离时。微锤条件下的UV应用虽然显着降低了成型力，但对板材的厚度分布有破坏作用，造成严重的减薄。目前的研究可以更好地了解超声波微锤及其对钣金成型过程的影响，