Use of progressive wave: a new multisource vibration technique to assist metal forming process

Abstract

Application of vibration in metal forming process has already shown numerous advantages in the past. It improves not only mechanical and surface properties of workpiece but the integration of vibration in metal forming process has also been helpful in the reduction of forming force required for the process. Majority of the work done before in this field is related to single vibration source vibration and its application in metal forming process. The aim of this work is to develop a mathematical model for multivibration assisted forging process. The combination of multi mechanical vibrations generates a complicated movement of lower die without deforming it. This developed mathematical model proves that movement is basically in the form of progressive wave in the lower die thus resulting local surface movement. In reality this movement can be generated by the vibration given by multi piezoelectric actuators. Based on this mathematical model, simulations using finite element software Forge2011 r have been performed to observe the presence of progressive wave in the workpiece. The simulations’ kinematics confirms the existence of progressive wave in the workpiece. Simulation results demonstrate the effect of progressive wave to reduce the forging force, reduction of friction on the lower surface of die and hence improvement the forging process. Based on the developed mathematical model and simulation results, design proposition for multi vibration assisted forging process has been presented in this work.