finite element analysis and experimental study of the ultrasonic vibration-assisted single point incremental forming (uvaspif) process

The mechanism of the single point incremental forming (spif) process is based on the localized plastic deformation of a sheet metal using a hemispherical-head tool that follows the path programmed into the controller of a cnc milling machine. in this process, no die is used under the sheet metal for support. the researchers' findings show that by applying ultrasonic vibration to forming processes, metallic samples are subject to plasticization, transiently and considerably. the beneficial results of applying ultrasonic vibration to the forming processes are due to the volume and surface effects that are related to a change in the properties of the material and also in frictional conditions. in this article, the ultrasonic vibration-assisted single point incremental forming (uvaspif) process was simulated in finite element software. the results of the numerical analysis showed that the ultrasonic excitation of the forming tool and an increase in the vibration amplitude reduced the friction force and the vertical component of the forming force. in the following, the results of the simulation process were compared with the experimental results at a frequency of 20 khz and 7.5 μm vibration amplitude. the study of the results showed good congruence between the values of the vertical component of the forming force resulting from the numerical analysis and the experimental test.