Ultrasonic Vibration- Assisted Hydrodynamic Deep Drawing: A Study on the Forming of Cylindrical Cups
Subject Areas : Journal of New Applied and Computational Findings in Mechanical Systemsmahdi sohrabkhani 1 , مهدی ظهور 2 , Shahram Etemadi Haghighi 3
1 - Ph.D. Student, Department of Mechanical Engineering , Science and Research Branch, Islamic Azad University, Tehran, Iran
2 - Associate professor, Department of Mechanical Engineering, K. N. Toosi University of Technology, Tehran, Iran
3 - Department of mechanical engineering, Science and Research Branch, Islamic Azad University, Tehran, Iran
Keywords: Ultrasonic vibrations, hydrodynamic deep drawing, cylindrical cup, finite element simulation, thinning ,
Abstract :
Hydrodynamic deep drawing assisted by ultrasonic vibrations is considered an advanced method compared to conventional hydrodynamic deep drawing, leading to improved formability and a reduction in the required forming force. In this innovative technology, the forming tool is subjected to oscillation with a low amplitude and high frequency. The primary objective of this study is to investigate the various parameters that influence the deformation behavior of thin-walled cylindrical parts produced by the ultrasonic vibration-assisted hydro-dynamic deep drawing process. To this end, using the finite element method, the die, acting as the vibrating tool, is longitudinally excited by forced vibrations with a frequency of 20 kHz and an amplitude of 5 µm. To validate the accuracy of the finite element model employed, the simulation outputs and experimental results were compared based on forming force and thickness distribution, demonstrating acceptable agreement. Subsequently, the effect of five parameters on the maximum thinning ratio of cylindrical cups was investigated. The results demonstrated that an increase in the friction coefficient between the sheet and the blank holder led to a 12.8% increase in the maximum thinning. Additionally, the punch and die corner radii, the increase in the friction coefficient between the sheet and the punch, and the increase in the gap between the die and the blank holder were the most effective parameters in reducing the maximum thinning, with contributions of 42.3%, 41.8%, 24.4%, and 22.5%, respectively.
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