Numerical Simulation of Ultrasonic Assisted Indentation Tube Forming

Document Type: Original Article

Authors

1 Department of Mechanical Engineering, Amirkabir University of Technology, Tehran, Iran

2 Department of Mechanical Engineering, Bu-Ali Sina University, Hamedan, Iran

Abstract

Indentation forming is an internal tube forming process in which a mandrel with a diameter slightly larger than that of the tube is pressed inside the tube and in so doing, creates the internal profile. Forming forces have a significant effect on the spring back, residual stress, quality of the inner surface, quality of tube dimensions, and tool wear. In this study, the forming process of CK45 steel tube by carbide tungsten tool in the presence of ultrasonic vibration has been simulated and the effect of ultrasonic on the forming mechanism has been investigated by introducing two regimes according to the forming conditions. The effects of tool feed-speed and amplitude of vibration on forming force reduction have been investigated. According to the simulation results, the main reason for the force reduction in the presence of longitudinal tube ultrasonic vibration is the intermittent phenomenon which is the continuous or impulsive regime. The critical amplitude which determines the borderline of continuous and impulsive regimes is obtained 38µm by the simulation of the process. The maximum force reduction obtained in continuous regime is 64.2% at the critical amplitude. The simulation results are consistent well with the previous experimental data.

Keywords


[1]     Garskii, F. K., Efromov, V. I., Effect of Ultrasound on the Decomposition of Solid Solutions, Izv. Akad. Nauk, Beloroussk SSR, Vol. 3, 1953.

[2]     Blaha, F., Langenecker, B., Dehnung Von Zink-Kristallen Unter Ultraschalleinwirkung, Naturwissenschaften, Vol. 42, 1955, pp. 556.

[3]     Siddiq, A., El Sayed, T., Ultrasonic-Assisted Manufacturing Processes: Variational Model and Numerical Simulations, Ultrasonics, Vol. 52, No. 4, 2012, pp. 521-9. DOI: 10.1016/j.ultras.2011.11.004.

[4]     Murakawa, M., Jin, M., The Utility of Radially and Ultrasonically Vibrated Dies in the Wire Drawing Process, Journal of Materials Processing Technology, Vol. ‎‎113, No. 1-3, 2001, pp. 81-86. DOI: 10.1016/S0924-0136(01)00635-5.

[5]     Murakawa, M., Jin, M., and Hayashi, M., Study on Semi Dry Wire Drawing Using Dlc Coated Dies, Surface and Coatings Technology, Vol. 177 –178, 2004, pp. 631–37. DOI: 10.1016/j.surfcoat.2003.08.057.

[6]     Huang, Z., Lucas, M., and Adams, M. J., Influence of Ultrasonics on Upsetting of a Model Paste, Ultrasonics, Vol. 40, No. 1-4,  2002, pp. 43–48. DOI: 10.1016/S0041-624X(02)00245-7.

[7]     Hayashi, M., Jin, M., and Thipprakmas, S., et al., Simulation of Ultrasonic-Vibration Drawing Using the Finite Element Method (Fem), Journal of Materials Processing Technology, Vol. 140, No. 1-3, 2003, pp. 30-35. DOI: 10.1016/s0924-0136(03)00699-x.

[8]     Mousavi, S., Akbari, A. A., Feizi, H., and Madoliat, R., Investigations on the Effects of Ultrasonic Vibrations in the Extrusion Process, Journal of Materials Processing Technology, Vol. 187-188, 2007, pp. 657-61. DOI: 10.1016/j.jmatprotec.2006.11.168.

[9]     Hung, J. C., Chiang, M. C., The Influence of Ultrasonic-Vibration on Double Backward-Extrusion of Aluminum Alloy, Proceedings of the World Congress on Engineering; WCE, London, U.K. 2009.

[10]  Pazand, K., Feizi, H., Using Artificial Neural Networks in Investigations on the Effects of Ultrasonic Vibrations on the Extrusion Process, Applied Mechanics and Materials, Vol. 52-54, 2011, pp. 103-08. DOI: 10.4028/www.scientific.net/AMM.52-54.103.

[11]  Abdullah, A., Paknejad, M., Dashti, S., Pak, A., and Beigi, A. M., Theoretical and Experimental Analyses of Ultrasonic-Assisted Indentation Forming of Tube, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 228, 2013, pp. 388-98. DOI: 10.1177/0954405413501502.

[12]  Simulia, D. S., Abaqus 6.13 User’s Manual, Dassault Systems, Providence, 2013.

[13]  Hensel, A., Poluchin, P. I., Poluchin, and W. P., Technologie Der Metallformung: Wiley, 1991.

[14]  Bruni, C., Forcellese, A., Gabrielli, F., Simoncini, M., and Montelatici, L., Evaluation of Friction Coefficient in Tube Drawing Processes, American Institute of Physics, Vol. 907, 2007, pp. 552-57. DOI: 10.1063/1.2729571.

[15]  Siegert, K., Ulmer, J., Superimposing Ultrasonic Waves on the Dies in Tube and Wire Drawing, Journal of Engineering Materials and Technology, Vol. 123, No. 4, 2001, pp. 517. DOI: 10.1115/1.1397779.

[16]  Paknejad, M., Abdullah, A., and Azarhoushang, B., Effects of High Power Ultrasonic Vibration on Temperature Distribution of Workpiece in Dry Creep Feed up Grinding, Ultrasonics Sonochemistry, Vol. 39, 2017, pp. 392-402. DOI: https://doi.org/10.1016/j.ultsonch.2017.04.029.