Ultrasonic Vibration- Assisted Hydrodynamic Deep Drawing: An Investigation into Sheet Thinning and Forming Force
Subject Areas : Journal of New Applied and Computational Findings in Mechanical Systemsmahdi sohrabkhani 1 , مهدی ظهور 2 , Shahram Etemadi Haghighi 3
1 - Ph.D. Student, Department of Mechanical Engineering , Science and Research Branch, Islamic Azad University, Tehran, Iran
2 - Associate professor, Department of Mechanical Engineering, K. N. Toosi University of Technology, Tehran, Iran
3 - Department of mechanical engineering, Science and Research Branch, Islamic Azad University, Tehran, Iran
Keywords: Ultrasonic Vibration, Hydrodynamic Deep Drawing, Cylindrical Cup, Forming Force, Thinning ,
Abstract :
Hydrodynamic deep drawing, is a prevalent metal forming technique in various industries, has consistently been a focal point of research work. Researchers have been dedicated to enhancing the efficiency of this process. A novel approach involving ultrasonic vibrations has emerged, with multiple studies demonstrating promising outcomes.
This paper aimed to examine the influence of ultrasonic vibrations applied to the die on the hydrodynamic deep drawing process. Employing the finite element method, ultrasonic vibrations at a frequency of 20 kHz and varying amplitudes were introduced to the die. Subsequently, the punch force and maximum thinning were compared between conventional hydrodynamic deep drawing and its counterpart incorporating ultrasonic vibrations.
Findings indicate that the radius of the punch corner is the most susceptible region during the forming process, experiencing the greatest thinning. The application of ultrasonic vibrations to the die resulted in a reduction of the forming force by 7.5 to 23% (dependent on the vibration amplitude) relative to the condition without ultrasonic vibrations. Moreover, the utilization of ultrasonic vibrations diminished thickness fluctuations by 10.2%. The maximum thinning in the radius of the punch corner exhibited a 6% improvement, and with an increase in vibration amplitude to 10 μm, the maximum thinning decreased by 11%. Nevertheless, excessive increases in vibration amplitude led to a resurgence in maximum thinning.
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