A Roadmap for Application of High Power Ultrasonic Vibrations in Metal Forming

Metal forming is a conventional manufacturing process that a material with simple form is subjected to plastic deformation and emerged to industrial end products. Reduction of forming forces and improving of products quality have been a promising object for investigators and artisans. To accede this purpose, primary methods such as increasing material temperature and modern methods such as use of high power low amplitude ultrasonic vibrations were introduced. In ultrasonic assisted forming, high power ultrasonic transducer produces low amplitude high frequency mechanical vibrations which transmitted to material subjected to deformation and contacting surfaces of tool/workpiece. Results show reduction of forming forces and tool wear as well as improving surface integrity and dimensional stability that lead to increasing production rate and process efficiency. By regarding to importance and capability of ultrasonic assisted metal forming, this paper is concerned with application of ultrasonic vibration on metal forming processes. To this purpose, fundamental and mechanisms of application of high power ultrasonic were introduces and discussed. Also, industrial future of this technology as well as its advantages, range of application and its restriction were mentioned.