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Ultrasonic-assisted manufacturing processes: variational model and numerical simulations.
1Computational Solid Mechanics Laboratory, Division of Physicial Science and Engineering, King Abdullah University of Science and Technology, Thuwal, Saudi Arabia.
Ultrasonics
|December 3, 2011
Summary
This study models ultrasonic assisted manufacturing, showing how ultrasonic energy softens materials during processes like sheet metal forming. The computational model accurately predicts material behavior under ultrasonic influence.
Area of Science:
- Computational mechanics
- Materials science
- Manufacturing engineering
Background:
- Ultrasonic assisted manufacturing (UAM) offers potential benefits in reducing forming forces and improving material properties.
- Accurate computational models are needed to understand and optimize UAM processes.
Purpose of the Study:
- To develop and validate a computational model for UAM processes.
- To investigate the influence of ultrasonic intensity on material behavior during deformation.
Main Methods:
- Modification of a variational porous plasticity model to incorporate ultrasonic softening effects.
- Inverse modeling using experimental data to identify material model parameters.
- Simulation of sheet metal forming, upsetting, and wire drawing processes.
Main Results:
- The developed model successfully accounts for instantaneous softening under ultrasonic energy application.
- The model demonstrates versatility and predictive capability across different UAM processes.
- The effect of ultrasonic intensity on manufacturing outcomes was investigated and qualitatively compared with literature.
Conclusions:
- The validated computational model provides a powerful tool for analyzing and optimizing ultrasonic assisted manufacturing.
- The study highlights the significant impact of ultrasonic intensity on material deformation and process outcomes.
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