Abstract
As an effective method for the fabrication of miniature metallic parts, the development of micro-forming process (MFP) is still restricted by the existence of size effect. To improve the micro-forming performance of metal material, ultrasonic vibration assisted MFP had been studied extensively for its superiorities in improving materials flow stress and reducing interfacial friction. However, from the literature available, the high frequency vibration was usually found to be superimposed on the forming tool while seldom on the workpiece. Our group developed a special porous sonotrode platform which can realize tool vibration and workpiece ultrasonic vibration independently. In this work, ultrasonic micro-extrusion experiments for copper T2 material under tool vibration and the workpiece vibration condition, respectively, were conducted for comparing the micro-forming characteristic of different vibration modes. The micro-extrusion experiment results of copper T2 show that the lower extrusion flow stress, the higher micro-extrusion formability and surface micro-hardness, and more obvious grain refinement phenomenon can be obtained under the workpiece vibration condition compared with that of tool vibration. These findings may enhance our understanding on different ultrasonic forming mechanisms and energy transmission efficiency under two different vibration modes.
Highlights
Micro-forming process (MFP) has attracted extensive attention in the manufacturing of micro metallic parts, which has been widely applied in aerospace, micro-electromechanical systems, medical science and other fields [1,2]
We found that the ultrasonic vibration in micro-forming process (MFP)
To analyze the ultrasonic micro-forming characteristics of different ultrasonic vibration modes, the ultrasonic vibration of micro-forming tool or workpiece would better be superimposed with the same ultrasonic system
Summary
Micro-forming process (MFP) has attracted extensive attention in the manufacturing of micro metallic parts, which has been widely applied in aerospace, micro-electromechanical systems, medical science and other fields [1,2]. Many researchers have found that the superposition of ultrasonic vibration on MFP was an effective way to change the interfacial friction condition, reduce the forming force and surface roughness during the micro-forming process. Hu et al studied the ultrasonic micro compression process of pure aluminum with a dynamic impact effect [3]. It was shown that the ultrasonic vibration of workpiece could change the plastic forming properties of material and generate an ultrasonic softening effect on the whole material during the plastic forming process [8]. Yusof Daud et al studied ultrasonic compression tests of aluminum with workpiece vibration by double slotted block horn and inverted ultrasonic system [9]
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