1. 7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming
Presenter: Prof. Gregory Wagner
Project PIs:
Gregory Wagnera, Jian Caoa, Brad Kinseyb
aNorthwestern University
bUniversity of New Hampshire, Durham

2. 7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming
Industrial Needs and Relevance:
Advanced processes that reduce production cost and increase yield rate.
Effective ways to form/bond difficult-to-form materials or parts with difficult-to-form geometries.
Processes that do not deteriorate the quality of formed parts, e.g., their mechanical properties, microstructures and surface finish.
NSF I/UCRC Planning Meeting

3. 7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming
Project Objectives:
Increase production rate and reduce cost by integrating multiple-step processes into a single-step process
Increase the process window in metal forming and bonding, especially for difficult-to-form materials
Alter microstructure and improve material properties through forming
NSF I/UCRC Planning Meeting

4. Electrically-Assisted Material Deformation
CCD camera for DIC strain measurement
Micro tensile machine
IR camera for recording temperature
Material: Nano-particle reinforced Ferritic Alloy
Zilin Jiang, Man-Kwan Ng, Qiang Zeng, Kornel Ehmann, Osman Anderoglu, Stuart Maloy, Jian Cao
“Electrically-Assisted Forming of Oxide Dispersion Strengthened Structural Materials”, MTS 2017
Valoppi, …., Cao, CIRP Annual 2016

5. Electrically-Assisted Mixed Double-Sided Incremental Forming (E-MDSIF)
Material: Ti6Al4V
Valoppi, B., Egea, A.J.S., Zhang, Z.X., Rojas, H.A.G., Ghiotti, A., Bruschi, S. and Cao, J. (2016) “A Hybrid Mixed Double-Sided Incremental Forming Method for Forming Ti6Al4V Alloy”, Annals of CIRP, Vol. 66 (1)
Valoppi, …., Cao, CIRP Annual 2016

6. Electrically-Assisted Bonding
Images of interface cross-sections in
(a) Al/Al at 60% thickness reduction, and (b) Al/Cu at 40% reduction sheets bonded by roll bonding with or without current.
Materials:
127 μm AA1100 Al alloy
127 μm 110 Cu alloy
127 μm stainless steel
Ng, M.K., Li, L.Y., Fan, Z.Y., Gao, R.X., Smith, E.S. III, Ehmann, K.F. and Cao, J. (2015) “Joining sheet metals by electrically-assisted roll bonding”, Annals of CIRP, Vol. 65(1), pp
Valoppi, …., Cao, CIRP Annual 2016

7. 7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming
Approach/Methodologies:
Electrically-Assisted Forming for Enhancing Formability and Joinability
Microrolling system
Electrically-assisted Roll bonding
Multi-physics modeling for the effect of continuous and pulsed current on forming and bonding
Microstructure and surface finish characterization of processed parts
Analytical modeling of bonding interface in EARB
NSF I/UCRC Planning Meeting

8. 7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming
Deliverables:
Multi-physics, multi-scale modeling of material behavior subject to electrically-assisted forming under continuous and pulsed current
Process design guideline for electrically-assisted forming (EAF)
Process design guideline for electrically-assisted roll bonding (EARB)

9. 7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming
Improved frictional conditions, and thus less surface galling, achieved.
Reduced forces required for micro-extrusion process.
Experimental set-up
Experimental set-up
Tooling
Surface condition results
Force results
Witthauer, A., Kim, G.Y., Faidley, L., Zou, Q., and Slaughter, J. (2010) “Effect of Ultrasonic Vibration on Micro-Extrusion Process”, International Conference on Micro Manufacturing (ICOMM), Madison, WI, April 5-8.
Bunget, C. and Ngaile, G. (2011) “Influence of Ultrasonic Vibration on Micro-Extrusion”, Ultrasonics, 51(5),
NSF I/UCRC Planning Meeting

10. 7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming
Approach/Methodologies:
Ultrasonic-Assisted Forming for Process Enhancement
Candidate processes that will yield economic benefits (micro/meso/macro scale proc., forming load patterns).
Availability of high power ultrasonic generators for industrial usage.
Tooling design requires reliable numerical modeling: Modal analysis and frequency response analysis (damping ratios which are function of mating surfaces are difficult to determine).
NSF I/UCRC Planning Meeting

11. 7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming
Approach/Methodologies:
Ultrasonic-Assisted Forming for Process Enhancement
Ultrasonic metal forming setup
Fundamental understanding of ultrasonic forming process: Effects of vibration frequency, mode, and amplitude on flow stress, microstructure and friction.
Tooling and system design guideline to acquire resonance frequencies.
Strategies to minimize ultrasonic energy input to assess process viability.
NSF I/UCRC Planning Meeting

12. 7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming
Deliverables:
Effects of vibration mode on friction under ultrasonic vibrations.
FEA simulations for tool and system design used in ultrasonic-assisted forming.
Characterizations of process and material formed by ultrasonic–assisted forming.
Variant mode shapes
NSF I/UCRC Planning Meeting

13. 7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming
Budget and Timeline:
- Estimated cost of project is $450K for three years.
Task / Milestone
Year 1
Year 2
Year 3 Q1 Q2 Q3 Q4
Material characterization
Multi-physics modeling
Microstructure Characterization
Design guideline
NSF I/UCRC Planning Meeting

14. 7. Hybrid (electrically/ultrasonic/thermal/…-assisted) forming
Discussion:
Are the industrial need and relevance accurately captured?
Are the objectives realistic and complete?
Are the approaches technically sound and appropriate?
Are there alternative implementation paths or better approaches?
Are the deliverables impactful to industrial partners?
Are the budget and timeline reasonable?
Are there conflicts with intellectual property or trade secrets?
List additional project specific questions are appropriate.
NSF I/UCRC Planning Meeting