Effects of Vibrations on Metal Forming Process: Analytical Approach and Finite Element Simulations

Abstract

Vibration assisted forming is one of the most recent and beneficial technique used to improve forming process. Effects of vibration on metal forming processes can be attributed to two causes. First, the volume effect links lowering of yield stress with the influence of vibration on the dislocation movement. Second, the surface effect explains lowering of the effective coefficient of friction by periodic reduction contact area. This work is related to vibration assisted forming process in viscoplastic domain. Impact of change in vibration waveform has been analyzed. For this purpose, two analytical models have been developed for two different types of vibration waveforms (sinusoidal and triangular). These models were developed on the basis of Slice method that is used to find out the required forming force for the process. Final relationships show that application of triangular waveform in forming process is more beneficial as compare to sinusoidal vibrations in terms of reduced forming force. Finite Element Method (FEM) based simulations were performed using Forge2008®and these confirmed the results of analytical models. The ratio of vibration speed to upper die speed is a critical factor in the reduction of the forming force.