Comparison Between Ultrasonic Vibration-Assisted Upsetting and Conventional Upsetting
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ONIC vibration has been widely applied to metal forming processes since the 1960s. The advantages of the application of the ultrasonic vibration in materials processing can be divided into two aspects: enhancing the forming processes and improving the microstructure and hence the mechanical properties of the specimen which was processed. For the first aspect, the superposition of ultrasonic vibration on the metal forming process is capable of reducing the forming force and the friction coefficient and increasing the forming limit. For example, Daud et al.[1] superimposed ultrasonic oscillations in aluminum compression tests and found that the flow stresses of the specimen were decreased. Daud et al.[2] also modeled their experiments using Abaqus/implicit and demonstrated that it was not sufficient to explain the effects of ultrasonic excitation in the metal forming processes only in terms of oscillatory stress superposition and contact friction. Their results suggest that it is necessary to understand the way ultrasonic energy is absorbed by aluminum in terms of its microstructure in YANXIONG LIU, Lecturer, is with the Hubei Key Laboratory of Advanced Technology of Automotive Parts, Wuhan University of Technology, Wuhan, P.R. China, and also with the Department of Mechanical Engineering Technology, Purdue University, 401 North Grant Street, West Lafayette, IN 47906. SERGEY SUSLOV, Postdoctor, is with the Department of Material Engineering, Purdue University. QINGYOU HAN, Professor, is with the Department of Mechanical Engineering Technology, Purdue University. LIN HUA, Professor, is with the Hubei Key Laboratory of Advanced Technology of Automotive Parts, Wuhan University of Technology. Contact email: [email protected] CLAUSE XU, Engineer, is with the Hans Tech, 3120 Bowfield way, West Lafayette, IN 47907. Manuscript submitted October 30, 2012. Article published online March 28, 2013 3232—VOLUME 44A, JULY 2013
order to explain the benefits for a range of metal forming processes. Huang et al.[3] studied the influence of ultrasonic vibration on the hot upsetting of a model paste and found that applying a short longitudinal ultrasonic pulse to the die reduces the mean forming force during upsetting. Hung et al.[4] also got the same result for the ultrasonic vibration hot upsetting of an aluminum specimen. Marakawa et al.[5] applied a radial ultrasonic vibration on the dies in the wire drawing process and found that the ultrasonic vibration can improve the surface quality of the wires and increase the critical drawing speed. Bunget and Ngaile[6] have investigated the ultrasonic vibration-assisted forward and combined microextrusion with the billet diameter from 10 mm down to 0.5 mm and fabricated small parts with good surface quality. Ultrasonic vibration has also been applied in the sheet metal forming process. Jimma,[7] Ashida,[8] and Oliver[9] have done extensive research in this area and found that seasoning crack of the drawn cups could be avoided and the limited drawing ratio could be increased when ultrasonic vibration
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