Ultrasonic-assisted manufacturing processes: Variational model and numerical simulations

We present a computational study of ultrasonic assisted manufacturing processes including sheet metal forming, upsetting, and wire drawing. A fully variational porous plasticity model is modified to include ultrasonic softening effects and then utilized to account for instantaneous softening when ultrasonic energy is applied during deformation. Material model parameters are identified via inverse modeling, i.e. by using experimental data. The versatility and predictive ability of the model are demonstrated and the effect of ultrasonic intensity on the manufacturing process at hand is investigated and compared qualitatively with experimental results reported in the literature.

► A constitutive model has been proposed for ultrasonic assisted manufacturing processes.
► The model is useful for simulating large deformation processes; sheet metal forming.
► Ultrasonic sheet metal forming, upsetting and wire drawing processes are simulated.
► Role of ultrasonic energy in reducing friction/forming forces is demonstrated.
► Evolution of porosity during sheet metal forming is also investigated.