1. National Institute of Standards and Technology (NIST) Advanced Manufacturing Technology Consortia (AMTech) Program Award Number: 70NANB14H056
Development of Roadmap and Consortium for Innovation in Sheet Metal Forming
Challenge
Code Group 3
3.1 Ultrasonic-Assisted Forming for Process Enhancement

2. 3.1 Ultrasonic-Assisted Forming for Process Enhancement
Objective: Improving metal forming processes through the application of ultrasonic vibration
System Requirements
Technical Benefits:
Reduced forming force
Reduced interface friction
Reduced tool wear
Better surface finish
Potential for matl. softening
Difficult-to-form geometry/
material may be feasible
Widen process window
(e.g. higher LDR )
Acquire resonance under loading condition
Minimize the energy losses.
Maximize the effects of ultrasonic oscillations
Offer stability
Ultrasonic metal forming setup
UNH - 28 October 2016
Sheet Metal Forming

3. 3.1 Ultrasonic-Assisted Forming for Process Enhancement
Technical and Non-Technical Challenges :
Research on ultrasonic forming has been carried out for decades, yet there is no widespread application of the technology in industry!
Fundamental understanding of ultrasonic forming process: Effects of vibration frequency, mode, and amplitude on flow stress, microstructure and friction.
Tooling and system design (to acquire resonance frequencies)
Strategies to minimize ultrasonic energy input (process viability)
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 )
Challenges to address
UNH - 28 October 2016
Sheet Metal Forming

4. 3.1 Ultrasonic-Assisted Forming for Process Enhancement
Path to Implementation:
Carry out ultrasonic experiments using a basic test set up such as plane strain sheet drawing and study the influence of ultrasound variables on friction force, microstructure, etc.
With the aid numerical modeling develop tooling design guidelines for ultrasonic assisted sheet forming. This will include classification of sheet forming processes that are ideal and cost effective for ultrasound technology.
Optimize ultrasonic energy usage by developing innovative methods for selectively applying ultrasonic vibrations in critical areas, particularly for large tooling.
In collaboration with manufactures of ultrasonic generators/systems, explore the potential for developing industrial scale ultrasonic systems with feedback module for tuning resonance frequency in real time.
Based on the input from the Center members regarding geometry, processes, and materials of interest and the knowledge gained from the above tasks, design experimental setup for ultrasonic-assisted deep drawing and conduct experiment under different ultrasonic conditions and assess the performance (tribological enhancement, microstructural changes, part quality, and load reduction) .
UNH - 28 October 2016
Sheet Metal Forming

5. 3.1 Ultrasonic-Assisted Forming for Process Enhancement
Discussion:
Timing: priority, resources available when needed?
Obstacles: technical & business?
Resources: level, type & issues?
Anything missing for active industry support?
Estimated benefits realistic & complete?
Technical and non-technical obstacles complete or over reaching?
Alternative implementation paths or better approaches?
Conflicts with intellectual property or trade secrets?
UNH - 28 October 2016
Sheet Metal Forming

6. 3.1 Ultrasonic-Assisted Forming for Process Enhancement
Example: Design issues encountered in micro extrusion
Variant mode shapes
UNH - 28 October 2016
Sheet Metal Forming