Effects of process parameters on force reduction and temperature variation during ultrasonic assisted incremental sheet forming process

  • Yangyang Long
  • Yanle Li
  • Jie Sun
  • Igor Ille
  • Jianfeng Li
  • Jens Twiefel
ORIGINAL ARTICLE
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Abstract

The incremental sheet forming (ISF) is an innovative dieless forming process featured with high formability and short lead time which is suitable for rapid prototyping and small volume production. The integration of ultrasonic (US) vibration into the ISF process can significantly reduce the forming force and bring other benefits. In this work, the impacts of process parameters including the sheet material, US power, feeding speed, and tool diameter, on force reduction and temperature increment were studied. The force reduction contains two components—the stress superposition-induced force reduction and acoustic softening-induced force reduction. The stress superposition-induced force reduction was analyzed by finite element simulation while the total force reduction was detected by experiments since currently, the unknown mechanism of the acoustic softening cannot be modeled. The temperature increment was measured by a high-speed infrared camera. The results show that the force reduction can go up to 56.58% and the temperature increment can be as high as 24.55 °C. In general, the material with a higher yield stress results in a higher force reduction and a higher temperature increment. A higher US power or a lower feeding speed can significantly enhance the force reduction and the interface temperature increment. The tool with a smaller diameter has a comparable effect as a larger tool, but a larger vibration amplitude is required.

Keywords

Ultrasonic vibration Incremental sheet forming Force reduction Interface temperature 

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Notes

Acknowledgements

The authors would like to thank the preparatory visit funding from Sino-German Center for Research Promotion (GZ1381). Dr. Yanle Li is also funded by National Natural Science Foundation of China (51605258), China Postdoctoral Science Foundation funded project (2016M592180), and Postdoctoral innovation project of Shandong Province (201701011).

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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Yangyang Long
    • 1
  • Yanle Li
    • 2
    • 3
  • Jie Sun
    • 2
    • 3
  • Igor Ille
    • 1
  • Jianfeng Li
    • 2
    • 3
  • Jens Twiefel
    • 1
  1. 1.Institute of Dynamics and Vibration ResearchLeibniz Universität HannoverHannoverGermany
  2. 2.School of Mechanical Engineering and Key Laboratory of High Efficiency and Clean Mechanical ManufactureShandong UniversityJinanChina
  3. 3.National Demonstration Center for Experimental Mechanical Engineering EducationShandong UniversityJinanChina

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