FE Simulation of Ultrasonic Back Extrusion

The main benefit of using ultrasonic vibrations in metal forming arises from the reduction in the mean forming force. In order to examine mechanisms responsible for this effect FE simulations of ultrasonic back extrusion using ABAQUS/Explicit were carried out. In two analysed models, vibration of frequency of 20 kHz was imposed on the punch. In the first model, the die and the punch were defined as rigid bodies and in the second, the punch was modelled as an elastic body, this being the innovative feature of the research. The punch vibrated in a longitudinal mode. Simulations were performed for amplitude of vibrations of 8.5μm and different punch velocities for both friction and frictionless conditions. Results showed that the amplitude and the mean forming force depended on the process velocity. Further, the decrease in the mean forming force might be partly explained by the reduction in the friction force due to changes in the direction and magnitude of the frictional stress over the vibration period. A...