EAGER/Collaborative Research: Fundamentals of Acousto-Plasticity and Tribology in Ultrasonically Enhanced Incremental Sheet Forming

EAGER/协作研究：超声增强增量板材成形中的声塑性和摩擦学基础

• 批准号: 1841589
• 负责人: Xun Liu
• 金额: $ 8.52万
• 依托单位: Ohio State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2018
• 资助国家: 美国
• 起止时间: 2018-09-01 至 2020-02-29
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1841589&HistoricalAwards=false
• 关键词: EAGER; Collaborative; Research; Fundamentals; Acousto

Today's fast-moving and competitive markets increase the frequency of product updates and rapidly expand demands for customized parts. Accordingly, high quality, low-cost prototyping and low volume manufacturing processes are desirable. No proven additive manufacturing or rapid prototyping approaches exist for sheet metals or large, thin parts - conventional additive manufacturing has too small of a build space and warps too much to produce parts such as automotive body panels. Incremental sheet forming (ISF), which utilizes a small tool to induce local deformation as it translates over the metal sheet, is a manufacturing approach that has been investigated recently because of its die-less setup, universal tooling and high flexibility. However, achieving dimensional and geometric accuracy as well as surface finish of the current ISF formed parts are a challenge, but the main drawback is the limited formability in the approach, leading to very high scrap rates. Ultrasonic vibration, known for its bulk material softening effects, surface modification and friction behavior improvements, offers promise in alleviating these concerns. This EArly-concept Grant for Exploratory Research (EAGER) award supports fundamental research to advance knowledge of the ultrasonic effects on material behavior in ISF processes. Success in this unique multidisciplinary study will lead to significant improved formability and process capabilities. Leveraging this new knowledge will expand ISF applications in various industries, such as aerospace, automotive, defense and medical, so that it has direct positive impact on the US national security and economic welfare. Students involved in the project will gain multidisciplinary knowledge and research capabilities including material, mechanical and manufacturing science and technologies. Outreach activities will emphasize the mentoring of women and underrepresented minorities. The objective of this project is an innovative improvement of the incremental sheet forming (ISF) process by effectively applying ultrasonic vibration to the tool during the forming operation. The potential benefits are to reduce forming force, increase formability, increase dimensional and geometrical tolerance and improve surface quality. This collaborative project includes an integrated experimental and modeling study of material behavior during tensile testing with ultrasonic vibration utilizing high speed digital image correlation analysis. The results will serve to design an effective approach for incorporating ultrasonic energy into ISF process. Ultrasonically assisted ISF will then be performed under different conditions. The interaction mechanisms between ultrasonic vibration and material deformation during ISF will be studied in terms of in-process variables, post-processing properties and multi-scale microstructure. The effect of ultrasonic vibration on both surface and bulk properties will be studied, including the impact on texture and grain size. The goals of this project are (1) understanding of the fundamental principles that govern the material behavior under ultrasonic vibration and (2) demonstration of the improvements enabled by ultrasonically assisted incremental forming process for complex free form geometries.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

当今快速发展且竞争激烈的市场增加了产品更新的频率，并迅速扩大了对定制零件的需求。因此，需要高质量、低成本的原型制作和小批量制造工艺。对于金属板材或大型、薄型零件，目前还没有经过验证的增材制造或快速原型制造方法——传统的增材制造的构建空间太小，而且变形太大，无法生产汽车车​​身面板等零件。渐进式板材成形 (ISF) 利用小型工具在金属板材上平移时引发局部变形，是一种最近受到研究的制造方法，因为它具有无模具设置、通用工具和高灵活性。然而，实现当前 ISF 成形零件的尺寸和几何精度以及表面光洁度是一个挑战，但主要缺点是该方法的成形性有限，导致废品率非常高。超声波振动以其散装材料软化效果、表面改性和摩擦行为改善而闻名，有望缓解这些问题。这项早期概念探索性研究资助 (EAGER) 奖项支持基础研究，以增进对 ISF 工艺中超声波对材料行为影响的了解。这项独特的多学科研究的成功将显着提高成形性和加工能力。利用这些新知识将扩大ISF在航空航天、汽车、国防和医疗等各个行业的应用，从而对美国的国家安全和经济福祉产生直接的积极影响。参与该项目的学生将获得包括材料、机械和制造科学与技术在内的多学科知识和研究能力。外展活动将强调对妇女和代表性不足的少数群体的指导。该项目的目标是通过在成形操作过程中有效地向工具施加超声波振动，对渐进式板材成形 (ISF) 工艺进行创新改进。潜在的好处是减少成形力、提高成形性、增加尺寸和几何公差以及提高表面质量。该合作项目包括利用高速数字图像相关分析，对超声波振动拉伸测试期间材料行为进行综合实验和建模研究。 研究结果将有助于设计一种将超声波能量融入 ISF 工艺的有效方法。然后将在不同条件下进行超声辅助 ISF。将从过程变量、后处理特性和多尺度微观结构方面研究 ISF 过程中超声振动与材料变形之间的相互作用机制。将研究超声波振动对表面和整体性能的影响，包括对织构和晶粒尺寸的影响。该项目的目标是 (1) 了解控制超声波振动下材料行为的基本原理，以及 (2) 展示超声波辅助增量成形工艺对复杂自由形状几何形状所带来的改进。该奖项反映了 NSF 的法定使命和通过使用基金会的智力优点和更广泛的影响审查标准进行评估，该项目被认为值得支持。

项目成果

Plastic deformation of pure copper in ultrasonic assisted micro-tensile test

• DOI: 10.1016/j.msea.2020.139364
• 发表时间: 2020-05-21
• 期刊: MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
• 影响因子: 6.4
• 作者: Kang, Jiarui;Liu, Xun;Xu, Mingjie
• 通讯作者: Xu, Mingjie