Optimization of Ultrasonic-Assisted Incremental Sheet Forming.

Area of Science:

• Materials Science
• Manufacturing Engineering
• Mechanical Engineering

Background:

• Ultrasonic vibration-assisted incremental sheet-forming (UISF) is known to reduce forming forces and enhance surface quality.
• Previous UISF studies focused on easily deformable materials and small step-down sizes.
• Larger step-down sizes and harder materials require further investigation for UISF effectiveness.

Purpose of the Study:

• To investigate the influence of ultrasonic vibration on force reduction in UISF for harder materials.
• To determine optimal process parameters (step-down size, feed rate) for UISF with larger step-down sizes.
• To develop equations for predicting force reduction based on plate thickness, step-down size, and feed rate.

Main Methods:

• Conducted a series of UISF experiments using aluminum alloy AA5052 with thicknesses of 0.5 mm and 1.0 mm.
• Varied step-down sizes from 0.5 mm to 1.5 mm and feed rates from 200 mm/min to 1200 mm/min.
• Analyzed the reduction in axial force (Fz) and tool movement resistance force (Fy) with and without ultrasonic vibration.

Main Results:

• Ultrasonic vibration significantly reduced axial force (Fz) and tool movement resistance force (Fy) when forming AA5052.
• Optimal equations for force reduction were developed based on experimental data for plate thickness.
• For 1.0 mm thickness, Fz and Fy reductions reached 58.73% and 69.17%; for 0.5 mm thickness, reductions were 64.17% and 71.98%.

Conclusions:

• UISF is effective in reducing forming forces for harder materials like AA5052, even at larger step-down sizes.
• The developed optimal equations provide a basis for predicting and achieving significant force reductions in UISF.
• This research expands the applicability of UISF to more challenging materials and forming conditions.