GOALI/Collaborative Research: Improving Incremental Sheet Forming by Ultrasonically Enhanced Material Deformation

GOALI/合作研究：通过超声波增强材料变形改进增量板材成型

• 批准号: 2019238
• 负责人: Xun Liu
• 金额: $ 29.81万
• 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: 2020
• 资助国家: 美国
• 起止时间: 2020-09-01 至 2024-02-29
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2019238&HistoricalAwards=false
• 关键词: GOALI; Collaborative; Research; Improving; Incremental

This Grant Opportunity for Academic Liaison with Industry (GOALI) award supports research that contributes to the understanding of ultrasonically-enhanced incremental sheet forming with funding from the Advanced Manufacturing Program in the Civil, Mechanical, and Manufacturing Innovation Division and from the Metals and Metallic Nanostructures Program in the Division of Materials Research. Despite the rapid development of ultra-high strength materials, their readiness to use is limited by limitations in the associated manufacturing processes, especially in the field of sheet metal forming. One promising solution is to temporarily soften the material during the forming process, which can be achieved with the assistance of ultrasonic energy. However, the underlying principles of this softening phenomenon remain elusive. Another benefit of applying ultrasonic energy is improved tribological behavior. Among forming technologies, incremental sheet forming is advantageous in rapid prototyping based on its universal tooling and high flexibility, which meet the increasingly competitive market demands of product updates and customization. However, achieving high geometric accuracy and surface finish quality are challenging. In this aspect, both the ultrasonic softening and modified friction can be harnessed as a unique process and property enhancement solution. The fundamental research of ultrasonic effects on material behavior facilitates effective incorporation of ultrasonic energy into incremental sheet forming, which greatly benefits sheet metal applications in industries such as aerospace, automotive and biomedical. Students involved in the project gain multidisciplinary knowledge and research experiences in materials, mechanical engineering and manufacturing. Students, particularly women and underrepresented minorities, have the opportunity to interact with GOALI partner Boeing engineers.This project aims to advance the fundamental knowledge of ultrasonic softening mechanisms on material deformation behavior. The research is to effectively utilize ultrasonic energy to enhance the incremental sheet forming (ISF) process based on both its bulk softening and modified surface tribological behavior. First, an innovative ultrasonically assisted (UA) micro-tensile testbed, equipped with an in situ high speed optical microscope imaging system, is developed. This enables digital image correlation analysis on the transient inter and intragranular strain field within the ultrasonic vibration cycle. Post mortem multiscale microstructure characterizations are then performed. A dislocation density-based crystal plasticity constitutive material model is developed to reveal the physical principles that are beyond experimental observations. Second, the UA-ISF process is comprehensively studied, in which relationships between the reduced forming force, increased forming accuracy, improved surface finish and the ISF and ultrasonic parameters are established. Finally, a coupled acousto-mechanical process model for UA-ISF is developed, which incorporates the ultrasonically affected material constitutive model developed in the first task. With experimental validations, this model would be utilized to optimize UA-ISF in forming parts with 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.

这项与行业联络的赠款机会（Goari）奖支持了研究，这有助于了解超声增强的增量表，并通过高级制造计划的资金在民用，机械和制造创新部门以及材料研究部中的金属和金属纳米结构计划的资金以及金属和金属纳米结构计划中进行了资金。尽管超高强度材料的发展迅速，但他们准备使用的准备就绪受到相关制造过程中的局限性的限制，尤其是在钣金形成领域。一种有希望的解决方案是在成型过程中暂时软化材料，这可以在超声波能量的帮助下实现。但是，这种软化现象的基本原理仍然难以捉摸。应用超声波能量的另一个好处是改善摩擦学行为。在成型技术中，基于其通用工具和高灵活性在快速原型制作中形成增量表是有利的，这些工具符合越来越多的产品更新和自定义的市场需求。但是，达到高几何准确性和表面饰面质量是具有挑战性的。在这方面，可以将超声软化和修改的摩擦作为独特的过程和属性增强解决方案利用。超声波对材料行为影响的基本研究有助于将超声波能量的有效纳入增量板形成中，这极大地有益于航空航天，汽车和生物医学等行业中的钣金应用。参与该项目的学生获得了材料，机械工程和制造业的多学科知识和研究经验。学生，尤其是妇女和代表性不足的少数民族，有机会与目标合作伙伴波音工程师互动。该项目旨在促进对材料变形行为的超声软化机制的基本知识。 这项研究是有效利用超声波能量来增强基于其散装软化和改良的表面摩擦学行为的增量表形成（ISF）过程。首先，开发了具有原位高速光学显微镜成像系统的创新超声辅助（UA）微张紧试验台。这使得超声振动周期内的瞬态间和刻度应变场对数字图像相关分析。然后进行验尸多尺度微观结构表征。开发了基于脱位密度的晶体可塑性组成材料模型，以揭示超出实验观察的物理原理。其次，全面研究了UA-FISF过程，其中减少的形成力，提高形成精度，改善的表面饰面以及ISF和超声波参数之间的关系。最后，开发了UA-FISF的耦合声学过程模型，该模型结合了第一个任务中开发的超声影响的材料本构模型。通过实验验证，该模型将用于优化UA-FISF，以形成复杂的自由形式几何形状。该奖项反映了NSF的法定任务，并被认为是值得通过基金会的知识分子和更广泛影响的评估评估标准的评估值得支持的。

项目成果

Crystal plasticity modeling of ultrasonic softening effect considering anisotropy in the softening of slip systems

• DOI: 10.1016/j.ijplas.2022.103343
• 发表时间: 2022-05
• 期刊: International Journal of Plasticity
• 影响因子: 9.8
• 作者: Jiarui Kang;Xun Liu;S. Niezgoda

Ultrasonic Effect on the Deformation Behavior and Microstructure Evolution of a TRIP-Assisted Steel

• DOI: 10.1007/s11661-021-06398-z
• 发表时间: 2021-07
• 期刊: Metallurgical and Materials Transactions A
• 作者: Jiarui Kang;Xun Liu

The effects of ultrasonic vibration on Portevin–Le Chatelier (PLC) effect and stress-strain behavior in aluminum alloy 2024

超声波振动对铝合金 Portevin-Le Chatelier (PLC) 效应和应力应变行为的影响 2024

• DOI: 10.1016/j.scriptamat.2022.115121
• 发表时间: 2023
• 期刊: Scripta Materialia
• 影响因子: 6
• 作者: Kang, Jiarui;Liu, Xun;Wang, Tianzhao
• 通讯作者: Wang, Tianzhao