Skip to main content
SpringerLink
Log in

Design, construction, and demonstration of a novel die system for deep drawing applications with utilization of ultrasonic vibrations

  • Technical Paper
  • Published:
Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

This study presents design, construction, and demonstration of a patented die system (UltraDRAW) used for deep drawing applications with utilization of ultrasonic vibrations. The developed system enables application of high-frequency vibrations onto the blank holder of die system in axial direction. Such design is considered to be effective in improving drawability of blank material, resulting in drawing of blanks with greater limiting drawing ratio (LDR) and lower forming load. For this purpose, an innovative ultrasonic horn with specific geometry, used directly as blank holder, was designed with steady-state harmonic response analyses using finite element method. To evaluate the performance of developed system, a series of cup drawing experiments using conventional and ultrasonically assisted die system were performed on cold-rolled low carbon steel sheets of DC01 and DC04 under dry and lubricated surface conditions. Compared to conventional drawing, UltraDRAW improved LDR and cup depth by 9.4% and 26.5% (for DC01) and 15.1% and 43.6% (for DC04) with reduction in forming load by 22.2% (for DC01) and 18.2% (for DC04).

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

References

  1. Chang QF, Li DY, Peng YH, Zeng XQ (2007) Experimental and numerical study of warm deep drawing of AZ31 magnesium alloy sheet. Int J Mach Tools Manuf 47:436–443. https://doi.org/10.1016/j.ijmachtools.2006.06.013

    Article  Google Scholar 

  2. Kim H, Sung JH, Sivakumar R, Altan T (2007) Evaluation of stamping lubricants using the deep drawing test. Int J Mach Tools Manuf 47:2120–2132. https://doi.org/10.1016/j.ijmachtools.2007.04.014

    Article  Google Scholar 

  3. Ali S, Hinduja S, Atkinson J, Bolt P, Werkhoven R (2008) The effect of ultra-low frequency pulsations on tearing during deep drawing of cylindrical cups. Int J Mach Tools Manuf 48:558–564. https://doi.org/10.1016/j.ijmachtools.2007.06.013

    Article  Google Scholar 

  4. Olguner S, Bozdana AT (2017) Influence of press ram pulsation on deep drawability of dual phase steel sheet. Acta Phys Pol A 132(3):742–745. https://doi.org/10.12693/APhysPolA.132.742

    Article  ADS  CAS  Google Scholar 

  5. Lin J, Zhao SD, Zhang ZY, Wang ZW (2009) Deep drawing using a novel hydromechanical tooling. Int J Mach Tools Manuf 49:73–80. https://doi.org/10.1016/j.ijmachtools.2008.07.014

    Article  CAS  Google Scholar 

  6. Irthiea I, Green G, Hashim S, Kriama A (2014) Experimental and numerical investigation on micro deep drawing process of stainless steel 304 foil using flexible tools. Int J Mach Tools Manuf 76:21–33. https://doi.org/10.1016/j.ijmachtools.2013.09.006

    Article  Google Scholar 

  7. Fartashvand V, Abdullah A, Vanini SAS (2017) Investigation of Ti–6Al–4V alloy acoustic softening. Ultrason Sonochem 38:744–749. https://doi.org/10.1016/j.ultsonch.2016.07.007

    Article  CAS  PubMed  Google Scholar 

  8. Yao Z, Kim GY, Wanga Z, Faidley L, Zou Q, Mei D, Chen Z (2012) Acoustic softening and residual hardening in aluminum: Modeling and experiments. Int J Plasticity 39:75–87. https://doi.org/10.1016/j.ijplas.2012.06.003

    Article  CAS  Google Scholar 

  9. Dauda Y, Lucas M, Huang Z (2007) Modelling the effects of superimposed ultrasonic vibrations on tension and compression tests of aluminium. J Mater Process Technol 186:179–190. https://doi.org/10.1016/j.jmatprotec.2006.12.032

    Article  CAS  Google Scholar 

  10. Langenecker B (1966) Effects of ultrasound on deformation characteristics of metals. IEEE Trans Sonics Ultrasonics 13:1–8. https://doi.org/10.1109/T-SU.1966.29367

    Article  Google Scholar 

  11. Hu J, Shimizu T, Yang M (2018) Investigation on ultrasonic volume effects: stress superposition, acoustic softening and dynamic impact. Ultrason Sonochem 48:240–248. https://doi.org/10.1016/j.ultsonch.2018.05.039

    Article  CAS  PubMed  Google Scholar 

  12. Lin J, Li J, Liu T, Zhu L, Chu X, Zhao G, Guan Y (2021) Evaluation of friction reduction and frictionless stress in ultrasonic vibration forming process. J Mater Process Technol 288:116881. https://doi.org/10.1016/j.jmatprotec.2020.116881

    Article  CAS  Google Scholar 

  13. Wu L, Zhao C, Cao M, Han X (2021) Effect of ultrasonic and low frequency vibrations on friction coefficient at die radius in deep drawing process. J Manuf Processes 71:56–69. https://doi.org/10.1016/j.jmapro.2021.09.008

    Article  Google Scholar 

  14. Smith AW (1977) An investigation of the deep drawing process with the application of ultrasonic oscillations. Ph.D. Thesis, The University of Aston, Birmingham, England

  15. Wen T, Gao R, Chen X (2012) Influence of high frequency vibration on deep drawing process of AZ31 sheet at room temperature. J Shanghai Jiaotong Univ 17:456–460. https://doi.org/10.1007/s12204-012-1305-x

    Article  Google Scholar 

  16. Lowe A, Hofmann A, Hauptmann M (2017) The use and application of ultrasonic vibrations in the 3D deformation of paper and cardboard. J Mater Process Technol 240:23–32. https://doi.org/10.1016/j.jmatprotec.2016.09.006

    Article  Google Scholar 

  17. Lowe A, Hauptmann M, Majschak JP (2017) The effect of ultrasonic oscillation on the quality of 3D shapes during deep-drawing of paperboard. BioResources 12(4):7178–7194

    Article  Google Scholar 

  18. Lowe A, Nikowski A, Hauptmann M (2020) Functional design of sonotrodes for deep-drawing of cardboard. BioResources 15(2):2763–2773

    Article  Google Scholar 

  19. Sheykholeslami M, Cinquemani S, Mazdak S (2018) Numerical study of the of ultrasonic vibration in deep drawing process of circular sections with rubber die. In: SPIE active and passive smart structures and integrated systems XII, Denver-Colorado, USA

  20. Yamazaki T, Hayakawa C, Kodama M, Jin M (2013) Deep drawing with ultrasonic vibration. J JSTP 54:47–51. https://doi.org/10.9773/sosei.54.47

    Article  CAS  Google Scholar 

  21. Kim SW, Son YG, Lee YS (2014) FEA and experiment investigation on the friction reduction for ultrasonic vibration assisted deep drawing. Trans Mater Process 23:413–418. https://doi.org/10.5228/KSTP.2014.23.7.413

    Article  Google Scholar 

  22. Huang YM, Wu YS, Huang JY (2014) The influence of ultrasonic vibration-assisted micro-deep drawing process. Int J Adv Manuf Technol 71:1455–1461. https://doi.org/10.1007/s00170-013-5553-1

    Article  Google Scholar 

  23. Cao M, Li J, Yuan Y, Zhao C (2017) Flexible die drawing of magnesium alloy sheet by superimposing ultrasonic vibration. Trans Nonferrous Met Soc China 27:163–171. https://doi.org/10.1016/S1003-6326(17)60019-0

    Article  CAS  Google Scholar 

  24. Zha C, Chen W (2019) Theories and experiments on effects of acoustic energy field in micro-square cup drawing. Int J Adv Manuf Technol 104:4791–4802. https://doi.org/10.1007/s00170-019-04338-1

    Article  Google Scholar 

  25. Malekipour E, Heidary H, Majd NS, Mazdak S, Sharifi E (2020) Effect of resonant frequency variation on the ultrasonically assisted deep drawing process: numerical and experimental study. Int J Adv Manuf Technol 106:2243–2264. https://doi.org/10.1007/s00170-019-04545-w

    Article  Google Scholar 

  26. Malekipour E, Sharifi E, Majd NS, Heidary H (2022) Observation on the behavior of ultrasonic micro-hammer and its effects on the deep drawing process: numerical simulation and experimental study. Ultrasonics 119:106566. https://doi.org/10.1016/j.ultras.2021.106566

    Article  CAS  PubMed  Google Scholar 

  27. Biddell DC, Sansome DH (1973) Deep drawing of cans with ultrasonic radial oscillations applied to the die. Ultrason Int Conf, London, England

  28. Young MJR, Sansome DH (1975) An oscillatory deep-drawing analogue. In: Proceedings of fifteenth international machine tool design and research conference, Palgrave Macmillan Publishers Limited, London, 551–559

  29. Biddell DC (1980) Ultrasonic deep-drawing and ironing with the aid of flat and profiled radial resonators. Acta Acust 45(1):14–24

    Google Scholar 

  30. Ashida Y, Aoyama H (2007) Press forming using ultrasonic vibration. J Mater Process Technol 187–188:118–122. https://doi.org/10.1016/j.jmatprotec.2006.11.174

    Article  CAS  Google Scholar 

  31. Siddiq A, El Sayed T (2012) Ultrasonic assisted manufacturing processes: variational model and numerical simulations. Ultrasonics 52:521–529. https://doi.org/10.1016/j.ultras.2011.11.004

    Article  PubMed  Google Scholar 

  32. Jimma T, Kasuga Y, Iwaki N, Miyazawa O, Mori E, Ito K, Hatano H (1998) An application of ultrasonic vibration to the deep drawing process. J Mater Process Technol 80–81:406–412. https://doi.org/10.1016/S0924-0136(98)00195-2

    Article  Google Scholar 

  33. Chu TH, Fuh KH, Yeh WC (2014) Modelling and analysis of deep drawing with utilization of vibrations and servo press using response surface methodology. Mater Res Innov 18:936–939. https://doi.org/10.1179/1432891714Z.000000000555

    Article  CAS  Google Scholar 

  34. Bozdana AT, Olguner S (2018) An ultrasonically assisted die system for deep drawing process and its operating method (in Turkish). Turkish Patent and Trademark Office, Patent No: TR2018-15097

  35. Olguner S, Bozdana AT (2020) Prediction of lankford coefficients for AA1050 and AA5754 aluminum sheets using uniaxial tensile tests and cup drawing experiments. In: Advances in design, simulation and manufacturing II, lecture notes in mechanical engineering, 438–446. https://doi.org/10.1007/978-3-030-22365-6_44

  36. Olguner S, Bozdana AT (2023) Ultrasonically assisted deep drawing process: Two-stage finite element analysis and experimental verification. J Fac Eng Archit Gazi Univ 38(1):257–268

    Google Scholar 

Download references

Acknowledgements

This work was financially granted by The Scientific and Technological Research Council of Türkiye (TUBITAK) with the project number of 315M300. The authors would like to express sincere thanks to TUBITAK for support. The die system developed within the scope of this study was registered by Turkish Patent and Trademark Office with the patent number of TR2018-15097.

Author information

Authors and Affiliations

  1. Mechanical Engineering Department, Engineering Faculty, Gaziantep University, 27310, Gaziantep, Turkey

    Sadık Olguner & Ali Tolga Bozdana

Authors
  1. Sadık Olguner
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ali Tolga Bozdana
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Methodology, investigation, validation, and manuscript draft preparation were performed by S. Olguner; conceptualization, supervision, resources, manuscript reviewing and editing were performed by A.T. Bozdana.

Corresponding author

Correspondence to Ali Tolga Bozdana.

Ethics declarations

Conflict of interest

The authors declare there is no conflicts of interest regarding the publication of this paper.

Additional information

Technical Editor: Lincoln Cardoso Brandao.

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Olguner, S., Bozdana, A.T. Design, construction, and demonstration of a novel die system for deep drawing applications with utilization of ultrasonic vibrations. J Braz. Soc. Mech. Sci. Eng. 46, 124 (2024). https://doi.org/10.1007/s40430-024-04689-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40430-024-04689-1

Keywords

Search

Navigation