Studies on Ultrasonic Assisted Incremental Forming

Abstract

Success of the sheet metal component production is largely depends upon formability of the material from which it is formed. Besides material property and geometry of the component, the process parameters play an important role. Incremental sheer metal forming is one of the process which enhance formability of the materials. It also imparts manufacturing flexibility and cost reduction. There are various Variants of incremental sheet metal forming process. A tool is traversed along the contour and fed in vertical direction to form the component. In this dissertation a novel method, ultrasonic assisted incremental sheet metal forming (USIF) has been studied to enhance the formability of the aluminium material. The tool was given ultrasonic vibration while it was traverse along the defined contour. An experimental set up for USIF has been developed. preliminary experiment were carried out to form point depression and a long depression. Using ordinary incremental sheet metal forming and ultrasonic assisted incremental sheet metal forming. It has been observed that the percentage thinning at fracture (36.33%)is more in USIF as compared to IF. Experiment were extended to form a pyramid shape vertical feed (0.25 to 4mm) were imparted to the tool. The tool was traversed along the square concentric contours. The thinning is found to be (26%) at fracture. when the vertical feed of the tool was 4mm.The maximum depth 13.11mm of the pyramid could be achieved in a single traverse with this vertical feed. USIF is formed to be promising technique far years to come.