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<p>As a flexible forming progress, single point incremental forming (SPIF) has excellent forming limit over traditional forming. Based on SPIF, the introduction of an energy field like ultrasonic vibration (UV) is an interesting method that could further improve the formability of materials. However, there are few theoretical explanations for the role of UV in SPIF. Thus, a failure model which considers the UV effect has been developed to evaluate the forming limit in UV-assisted SPIF. A truncated cone part was formed using A1060 and Cu-Al sheet for verification. The performance of the theoretical model is confirmed by comparing with experimental results, and the mechanics of formability variation in UV-assisted SPIF have been explained through the theory of surface effect, including vibration effect and heat effect. The influence of process parameters on the formability of both materials, such as amplitude and feed rate, is also analyzed. Meanwhile, the states of equivalent plastic strains and tress triaxiality at fracture location are discussed in SPIF with/ without UV and Nakajima test. The proposed model and method are expected to provide a benchmark and its scientific interpretation of the UV effect in SPIF.</p>

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Theoretical and experimental investigation on the forming limit of metal sheets in ultrasonic vibration-assisted SPIF

  • 期刊论文

  • 发表日期：

    2025年6月17日

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  • Juan Liao,
  • Nie Zhang,
  • Jinhang Qian,
  • Mangong Zhang,
  • Xin Xue

摘要

As a flexible forming progress, single point incremental forming (SPIF) has excellent forming limit over traditional forming. Based on SPIF, the introduction of an energy field like ultrasonic vibration (UV) is an interesting method that could further improve the formability of materials. However, there are few theoretical explanations for the role of UV in SPIF. Thus, a failure model which considers the UV effect has been developed to evaluate the forming limit in UV-assisted SPIF. A truncated cone part was formed using A1060 and Cu-Al sheet for verification. The performance of the theoretical model is confirmed by comparing with experimental results, and the mechanics of formability variation in UV-assisted SPIF have been explained through the theory of surface effect, including vibration effect and heat effect. The influence of process parameters on the formability of both materials, such as amplitude and feed rate, is also analyzed. Meanwhile, the states of equivalent plastic strains and tress triaxiality at fracture location are discussed in SPIF with/ without UV and Nakajima test. The proposed model and method are expected to provide a benchmark and its scientific interpretation of the UV effect in SPIF.