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The influence of ultrasonic vibration on parts properties during incremental sheet forming

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Abstract

The integration of ultrasonic vibration into sheet forming process can significantly reduce the forming force and bring benefits including the enhancement of surface quality, the enhancement of formability and the reduction of spring-back. However, the influencing mechanisms of the high-frequency vibration on parts properties during the incremental sheet forming (ISF) process are not well known, preventing a more efficient forming system. This paper comprehensively investigates the effects of different process parameters (vibration amplitude, step-down size, rotation speed and forming angle) on the micro-hardness, minimum thickness, forming limit and residual stress of the formed parts. First, a series of truncated pyramids were formed with an experimental platform designed for the ultrasonic-assisted incremental sheet forming. Then, micro-hardness tests, minimum thickness measurements and residual stress tests were performed for the formed parts. The results showed that the surface micro-hardness of the formed part was reduced since the vibration stress induced by the ultrasonic vibration within the material which eliminated the original internal stress. The superimposed ultrasonic vibration can effectively uniform the residual stress and thickness distribution, and improve the forming limit in the case of the small deformation rate. In addition, through the tensile fracture analysis of the formed part, it is shown that the elongation of material is improved and the elastic modulus and hardening index are decreased. The findings of the present work lay the foundation for a better integration of the ultrasonic vibration system into the incremental sheet forming process.

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Acknowledgement

This work is supported by the National Natural Science Foundation of China (Grant Nos. 51975328, 51605258), the Postdoctoral Innovation Project of Shandong Province (Grant No. 201701011) and Young Scholars Program of Shandong University (Grant No. 2018WLJH55).

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Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Yan-Le Li, Zi-Jian Wang, Wei-Dong Zhai, Zi-Nan Cheng & Fang-Yi Li

  2. National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan, 250061, China

    Yan-Le Li, Zi-Jian Wang, Wei-Dong Zhai, Zi-Nan Cheng & Fang-Yi Li

  3. School of Mechanical Engineering and Automation, Beihang University, Beijing, 100083, China

    Xiao-Qiang Li

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  1. Yan-Le Li
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  2. Zi-Jian Wang
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  4. Zi-Nan Cheng
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  5. Fang-Yi Li
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Correspondence to Xiao-Qiang Li.

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Li, YL., Wang, ZJ., Zhai, WD. et al. The influence of ultrasonic vibration on parts properties during incremental sheet forming. Adv. Manuf. 9, 250–261 (2021). https://doi.org/10.1007/s40436-021-00347-0

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  • DOI: https://doi.org/10.1007/s40436-021-00347-0

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