Macroscopic mechanism of ultrasonic vibration in ultrasonic-assisted metal forming
Ultrasonic vibration-assisted metal forming has gained increasing attention and applications recently, but the mechanism of ultrasonic effects is still not clear. In this paper, a new finite element method to simulate all ultrasonic effects in metal forming was proposed, and the volume effect and su...
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| Format: | Article |
| Language: | English |
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Elsevier
2023-05-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785423010335 |
| _version_ | 1827920131882221568 |
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| author | Jiqiang Zhai Yanjin Guan Ya Liu Fengjiao Chen Jun Lin |
| author_facet | Jiqiang Zhai Yanjin Guan Ya Liu Fengjiao Chen Jun Lin |
| author_sort | Jiqiang Zhai |
| collection | DOAJ |
| description | Ultrasonic vibration-assisted metal forming has gained increasing attention and applications recently, but the mechanism of ultrasonic effects is still not clear. In this paper, a new finite element method to simulate all ultrasonic effects in metal forming was proposed, and the volume effect and surface effect were quantitatively analyzed in upsetting and U-groove extrusion. It was found that the ultrasonic effects were quite different in upsetting and extrusion. In U-groove extrusion, the acoustic softening effect reduced the flow stress of the material by 20.0 MPa, far less than that in upsetting (91.7 MPa). The friction decreased by 82.7% due to the surface effect, which was more significant than that in upsetting (decreased by 58.3% and 33.3% at the top and bottom interfaces). Ultrasonic vibration increased the feature height in U-groove extrusion from 0.653 mm to 1.427 mm with a growth rate of 118.5%. The acoustic softening effect increased the feature height by 0.063 mm (8% of the total increase), while the surface effect increased the feature height by 0.711 mm (92% of the total). The surface effect plays a key role in affecting material flow in extrusion. It is suggested that this method could accurately reflect the deformation behavior of materials with ultrasonic assistance, and is of great value for process design and in-depth study of the microscopic mechanism in ultrasonic forming. |
| first_indexed | 2024-03-13T04:08:13Z |
| format | Article |
| id | doaj.art-4f057df5846a4ea28ad8f8722109d29d |
| institution | Directory Open Access Journal |
| issn | 2238-7854 |
| language | English |
| last_indexed | 2024-03-13T04:08:13Z |
| publishDate | 2023-05-01 |
| publisher | Elsevier |
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| series | Journal of Materials Research and Technology |
| spelling | doaj.art-4f057df5846a4ea28ad8f8722109d29d2023-06-21T06:57:37ZengElsevierJournal of Materials Research and Technology2238-78542023-05-012478527864Macroscopic mechanism of ultrasonic vibration in ultrasonic-assisted metal formingJiqiang Zhai0Yanjin Guan1Ya Liu2Fengjiao Chen3Jun Lin4Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan 250061, PR ChinaCorresponding author.; Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan 250061, PR ChinaKey Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan 250061, PR ChinaKey Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan 250061, PR ChinaKey Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan 250061, PR ChinaUltrasonic vibration-assisted metal forming has gained increasing attention and applications recently, but the mechanism of ultrasonic effects is still not clear. In this paper, a new finite element method to simulate all ultrasonic effects in metal forming was proposed, and the volume effect and surface effect were quantitatively analyzed in upsetting and U-groove extrusion. It was found that the ultrasonic effects were quite different in upsetting and extrusion. In U-groove extrusion, the acoustic softening effect reduced the flow stress of the material by 20.0 MPa, far less than that in upsetting (91.7 MPa). The friction decreased by 82.7% due to the surface effect, which was more significant than that in upsetting (decreased by 58.3% and 33.3% at the top and bottom interfaces). Ultrasonic vibration increased the feature height in U-groove extrusion from 0.653 mm to 1.427 mm with a growth rate of 118.5%. The acoustic softening effect increased the feature height by 0.063 mm (8% of the total increase), while the surface effect increased the feature height by 0.711 mm (92% of the total). The surface effect plays a key role in affecting material flow in extrusion. It is suggested that this method could accurately reflect the deformation behavior of materials with ultrasonic assistance, and is of great value for process design and in-depth study of the microscopic mechanism in ultrasonic forming.http://www.sciencedirect.com/science/article/pii/S2238785423010335Ultrasonic vibrationPlastic formingNumerical simulationVolume effectSurface effect |
| spellingShingle | Jiqiang Zhai Yanjin Guan Ya Liu Fengjiao Chen Jun Lin Macroscopic mechanism of ultrasonic vibration in ultrasonic-assisted metal forming Journal of Materials Research and Technology Ultrasonic vibration Plastic forming Numerical simulation Volume effect Surface effect |
| title | Macroscopic mechanism of ultrasonic vibration in ultrasonic-assisted metal forming |
| title_full | Macroscopic mechanism of ultrasonic vibration in ultrasonic-assisted metal forming |
| title_fullStr | Macroscopic mechanism of ultrasonic vibration in ultrasonic-assisted metal forming |
| title_full_unstemmed | Macroscopic mechanism of ultrasonic vibration in ultrasonic-assisted metal forming |
| title_short | Macroscopic mechanism of ultrasonic vibration in ultrasonic-assisted metal forming |
| title_sort | macroscopic mechanism of ultrasonic vibration in ultrasonic assisted metal forming |
| topic | Ultrasonic vibration Plastic forming Numerical simulation Volume effect Surface effect |
| url | http://www.sciencedirect.com/science/article/pii/S2238785423010335 |
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