Skip to main content
SpringerLink
Log in

Effects of process parameters on force reduction and temperature variation during ultrasonic assisted incremental sheet forming process

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The incremental sheet forming (ISF) is an innovative dieless forming process featured with high formability and short lead time which is suitable for rapid prototyping and small volume production. The integration of ultrasonic (US) vibration into the ISF process can significantly reduce the forming force and bring other benefits. In this work, the impacts of process parameters including the sheet material, US power, feeding speed, and tool diameter, on force reduction and temperature increment were studied. The force reduction contains two components—the stress superposition-induced force reduction and acoustic softening-induced force reduction. The stress superposition-induced force reduction was analyzed by finite element simulation while the total force reduction was detected by experiments since currently, the unknown mechanism of the acoustic softening cannot be modeled. The temperature increment was measured by a high-speed infrared camera. The results show that the force reduction can go up to 56.58% and the temperature increment can be as high as 24.55 °C. In general, the material with a higher yield stress results in a higher force reduction and a higher temperature increment. A higher US power or a lower feeding speed can significantly enhance the force reduction and the interface temperature increment. The tool with a smaller diameter has a comparable effect as a larger tool, but a larger vibration amplitude is required.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Leszak E (1967) Apparatus and process for incremental dieless forming. USA Patent 3342051A

  2. Kitazawa K, Wakabayashi A, Murata K, Yaejima K (1996) Metal-flow phenomena in computerized numerically controlled incremental stretch-expanding of aluminum sheets, vol 46. vol 2. Keikinzoku Tokyo

  3. Jeswiet J (2001) Incremental single point forming. Trans North Am Manuf Res Inst SME 29:75–79

    Google Scholar 

  4. Amino M, Mizoguchi M, Terauchi Y, Maki T (2014) Current status of “Dieless” Amino's incremental forming. Procedia Engineering 81(0):54–62

    Article  Google Scholar 

  5. Ambrogio G, Cozza V, Filice L, Micari F (2007) An analytical model for improving precision in single point incremental forming. J Mater Process Technol 191(1–3):92–95

    Article  Google Scholar 

  6. Allwood JM, Braun D, Music O (2010) The effect of partially cut-out blanks on geometric accuracy in incremental sheet forming. J Mater Process Technol 210(11):1501–1510

    Article  Google Scholar 

  7. Lu H, Kearney M, Li Y, Liu S, Daniel WJT, Meehan PA (2016) Model predictive control of incremental sheet forming for geometric accuracy improvement. Int J Adv Manuf Technol 82(9–12):1781–1794

    Article  Google Scholar 

  8. Durante M, Formisano A, Langella A (2010) Comparison between analytical and experimental roughness values of components created by incremental forming. J Mater Process Technol 210(14):1934–1941

    Article  Google Scholar 

  9. Hamilton K, Jeswiet J (2010) Single point incremental forming at high feed rates and rotational speeds: surface and structural consequences. CIRP Ann Manuf Technol 59(1):311–314

    Article  Google Scholar 

  10. Mohammadi A, Vanhove H, Van Bael A, Duflou JR (2016) Towards accuracy improvement in single point incremental forming of shallow parts formed under laser assisted conditions. Int J Mater Form 9(3):339–351

    Article  Google Scholar 

  11. Malhotra R, Cao J, Beltran M, Xu D, Magargee J, Kiridena V, Xia ZC (2012) Accumulative-DSIF strategy for enhancing process capabilities in incremental forming. CIRP Ann Manuf Technol 61(1):251–254

    Article  Google Scholar 

  12. Liu R, Lu B, Xu D, Chen J, Chen F, Ou H, Long H (2016) Development of novel tools for electricity-assisted incremental sheet forming of titanium alloy. Int J Adv Manuf Technol 85(5):1137–1144

    Article  Google Scholar 

  13. Cui XH, Mo JH, Li JJ, Zhao J, Zhu Y, Huang L, Li ZW, Zhong K (2014) Electromagnetic incremental forming (EMIF): a novel aluminum alloy sheet and tube forming technology. J Mater Process Technol 214(2):409–427

    Article  Google Scholar 

  14. Rasoli MA, Abdullah A, Farzin M, Tehrani AF, Taherizadeh A (2012) Influence of ultrasonic vibrations on tube spinning process. J Mater Process Technol 212(6):1443–1452

    Article  Google Scholar 

  15. Blaha F, Langenecker B (1955) Dehnung von Zink-Kristallen unter Ultraschalleinwirkung. Naturwissenschaften 45(20):556–556 (in German)

    Article  Google Scholar 

  16. Nevill GE, Brotzen FR (1957) The effect of vibrations on the static yield strength of a low-carbon steel. Proc Am Soc Test Mater 57:751–758

    Google Scholar 

  17. Blaha F, Langenecker B (1959) Ultrasonic investigation of the plasticity of metal crystals. Acta Metall 7(2):93–100

    Article  Google Scholar 

  18. Daud Y, Lucas M, Huang Z (2007) Modelling the effects of superimposed ultrasonic vibrations on tension and compression tests of aluminium. J Mater Process Technol 186(1–3):179–190

    Article  Google Scholar 

  19. Daud Y, Lucas M, Huang Z (2006) Superimposed ultrasonic oscillations in compression tests of aluminium. Ultrasonics 44(SUPPL):e511–e515

    Article  Google Scholar 

  20. Aziz SA, Lucas M (2012) Characterising the acoustoplastic effect in an ultrasonically assisted metal forming process. IOP Conf Ser Mater Sci Eng 42:012017. https://doi.org/10.1088/1757-899X/42/1/012017

    Article  Google Scholar 

  21. Yao Z, Kim GY, Faidley L, Zou Q, Mei D, Chen Z (2012) Effects of superimposed high-frequency vibration on deformation of aluminum in micro/meso-scale upsetting. J Mater Process Technol 212(3):640–646

    Article  Google Scholar 

  22. Storck H, Littmann W, Wallaschek J, Mracek M (2002) The effect of friction reduction in presence of ultrasonic vibrations and its relevance to travelling wave ultrasonic motors. Ultrasonics 40(1–8):379–383

    Article  Google Scholar 

  23. Vahdati M, Mahdavinejad R, Amini S (2015) Investigation of the ultrasonic vibration effect in incremental sheet metal forming process. Proceedings of the Institution of mechanical engineers, Part B J Eng Manuf

  24. Amini S, Hosseinpour Gollo A, Paktinat H (2016) An investigation of conventional and ultrasonic-assisted incremental forming of annealed AA1050 sheet. Int J Adv Manuf Technol:1–10

  25. Qi H, Wen DH, Lu CD, Li G (2016) Numerical and experimental study on ultrasonic vibration-assisted micro-channelling of glasses using an abrasive slurry jet. Int J Mech Sci 110:94–107

    Article  Google Scholar 

Download references

Acknowledgements

The authors would like to thank the preparatory visit funding from Sino-German Center for Research Promotion (GZ1381). Dr. Yanle Li is also funded by National Natural Science Foundation of China (51605258), China Postdoctoral Science Foundation funded project (2016M592180), and Postdoctoral innovation project of Shandong Province (201701011).

Author information

Authors and Affiliations

  1. Institute of Dynamics and Vibration Research, Leibniz Universität Hannover, Appelstr. 11, 30167, Hannover, Germany

    Yangyang Long, Igor Ille & Jens Twiefel

  2. School of Mechanical Engineering and Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Shandong University, No. 17923 Jingshi Rd, Jinan, 250061, China

    Yanle Li, Jie Sun & Jianfeng Li

  3. National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan, 250061, China

    Yanle Li, Jie Sun & Jianfeng Li

Authors
  1. Yangyang Long
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yanle Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jie Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Igor Ille
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Jianfeng Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jens Twiefel
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Yanle Li.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Long, Y., Li, Y., Sun, J. et al. Effects of process parameters on force reduction and temperature variation during ultrasonic assisted incremental sheet forming process. Int J Adv Manuf Technol 97, 13–24 (2018). https://doi.org/10.1007/s00170-018-1886-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-1886-0

Keywords

Search

Navigation