Investigation on Deformation Behavior in the Surface of Metal foil with Ultrasonic Vibration-Assisted Micro-Forging

Excitation of the acoustic field leading to the Blaha effect affects the plasticity of the material significantly in ultrasonic vibration-assisted forming. In a micro-forming field, the effects are more significant in the deformation in surface of materials [1]-[3], in which reduction of the surface roughness based on the increasing of plastic deformation of surface asperity was effective [4]. On the other hand, the effect on deformation behavior of the bulk region indicted reduction in the yield stress of materials, and not only acoustic effect [5], but also impact effect is found to generate a large amount of dislocation and produce plastic deformation [6][7]. However, the effect on the bulk is more significant as that on the surface. Differences in the effect on the surface and the bulk are not clarified. In this study, the mechanism of the deformation in the surface of the material with ultrasonic vibration assistance is investigated and compared with that in the bulk. Forging tests using a newly developed ultrasonic vibrator were carried out on pure Cu foils with various process conditions. The longitudinal vibration frequency of the ultrasonic transducer is 60∓2kHz, and the vibration amplitude is in an adjustable range of 0~10μm. Forging test was carried out at different initial stress, specimen size and amplitude. The difference in acoustic softening and impact effects on the surface and the bulk was discussed.

Experimental Study of Ultrasonic Vibration Effects on Punch Radial in Sheet Hydroforming Process

Nowadays, one of the metal forming processes that are widely used in industries is sheet hydroforming. Because of high complexity and sensitivity, this process needs precise calculations in the die and method to control metal flow correctly and prevent defects. Therefore recently, new processes were combined to this process to increase precision and effectiveness. For example, ultrasonic vibration assistance forming. Using hydroforming and ultrasonic vibration as new methods were studied in several research types separately, and each of them redounded to different analyses and improvements in the process. Even synchronic use of these two methods was studied in some metal forming processes such as tube hydroforming, but it has not been studied in sheet hydroforming. Therefore the aim of this research is the experimental study of St14 sheet hydroforming ultrasonic vibration assistance. For this purpose, ultrasonic vibration (with 20 KHz frequency and 4μm amplitude) was applied to a hydromechanical deep drawing die into punch radial in the hydroforming process. Then process parameters consisting of LDR, maximum height, forming force, safe working zone, and thickness distribution were determined and compared in four case states conventional deep drawing(CDD), hydroforming deep drawing(HDD), ultrasonic vibration assistance deep drawing(UDD) and ultrasonic vibration assistance hydroforming deep drawing(UHDD). Results indicated that applying ultrasonic vibration into the sheet hydroforming process increases LDR and the maximum height of the cup, decreases forming force and develops a safe working zone. Also was very effective in thickness distribution and decrease of sheet thinning in critical sections.

Development and Investigation of an Inexpensive Low Frequency Vibration Platform for Enhancing the Performance of Electrical Discharge Machining Process

Difficulty in debris removal and the transport of fresh dielectric into discharge gap hinders the process performance of electrical discharge machining (EDM) process. Therefore, in this work, an economical low frequency vibration platform was developed to improve the performance of EDM through vibration assistance. The developed vibratory platform functions on an eccentric weight principle and generates a low frequency vibration in the range of 0–100 Hz. The performance of EDM was evaluated in terms of the average surface roughness (Ra), material removal rate (MRR), and tool wear rate (TWR) whilst varying the input machining parameters viz. the pulse-on-time (Ton), peak current (Ip), vibration frequency (VF), and tool rotational speed (TRS). The peak current was found to be the most significant parameter and contributed by 78.16%, 65.86%, and 59.52% to the Ra, MRR, and TWR, respectively. The low frequency work piece vibration contributed to an enhanced surface finish owing to an improved flushing at the discharge gap and debris removal. However, VF range below 100 Hz was not found to be suitable for the satisfactory improvement of the MRR and reduction of the TWR in an electrical discharge drilling operation at selected machining conditions.

Ultrasonic Vibration-Assisted Ball Burnishing Tool for a Lathe Characterized by Acoustic Emission and Vibratory Measurements

This paper focuses on a resonant system used to induce a low-amplitude movement and ultrasonic frequency to complement a ball burnishing process on a lathe. The system was characterized through the combination of different techniques. A full vibratory characterization of this process was undertaken with the purpose of demonstrating that the mechanical system—composed of the tool and the machine—does not present resonance phenomena during the execution of the operation that could lead to eventual failure. This dynamic analysis validates the adequateness of the tool when attached to an NC lathe, which is important to guarantee its future implementation in actual manufacturing contexts. A further aim was to confirm that the system succeeds in transmitting an oscillating signal throughout the material lattice. To this end, different static and dynamic techniques that measure different vibration ranges—including impact tests, acoustic emission measurement, and vibration measurement—were combined. An operational deflection shape model was also constructed. Results demonstrate that the only high frequency appearing in the process originated in the tool. The process was not affected by the presence of vibration assistance, nor by the burnishing preload or feed levels. Furthermore, the frequency of the assisting ultrasonic vibration was characterized and no signal due to possible damage in the material of the specimens was detected. These results demonstrate the suitability of the new tool in the vibration-assisted ball burnishing process.

Combination of Acoustic Emission and Vibratory Measurements to Characterize an Ultrasonic Vibration Assisted Ball Burnishing Tool for a Lathe

In this paper, a resonant system that produces a movement of low amplitude and ultrasonic frequency is used to achieve the vibration assistance in a ball-burnishing process. A full vibration characterization of this process performed in a lathe was done. It is carried out by a new tool designed in the research group of the authors. Its purpose is to demonstrate that the machine and the tool do not have any resonance problem during the process and to prevent possible failures. The analysis of this dynamic behaviour permits to validate the suitability of the tool when it is anchored to a numerical control lathe. This is very important for its future industrial implementation. It is also intended to confirm that the system adequately transmits vibrations through the material. To do this, a methodology to validate the dynamic tool behaviour was developed. Several techniques that combine the usual and ultrasonic vibration ranges through static and dynamic measurements were merged: vibration and acoustic emission measurements. An operational deflection shape (ODS) exercise has been also performed. Results show the suitability of the tool used to transmit the assistance vibrations, and that no damage is produced in the material in any case.

Superficial Effects of Ball Burnishing on TRIP Steel AISI 301LN Sheets

This paper explores the consequences of applying an ultrasonic vibration-assisted ball burnishing process and its non-vibration assisted version on the topology and subsurface microstructure of a transformation-induced plasticity AISI 301LN alloy. More specifically, four different metallographic conditions provided as 1.5-mm thickness sheets and characterized by different starting martensite content (3, 10, 20 and 40 wt.%) are included in the study. Ball burnishing was performed along the lamination direction and perpendicular to it. Results show that the effect of ball burnishing is strongly correlated with the pre-existing microstructure. The steel containing the lowest quantity of initial martensite is the most affected by the process, achieving a higher residual hardening effect, similar to the untreated steel with an original martensitic content of around 40 wt.%. Moreover, the process succeeds in generating a 100-nm thick nanograin layer under the plate subsurface. Finally, no conspicuous effect of the application of vibration assistance was observed, which encourages the application of alternative measurement techniques in future works to define its effect on the properties after being ball burnished.