The use and application of ultrasonic vibrations in the 3D deformation of paper and cardboard

In this paper the deep drawing of cups from fiber-based materials, which is explored for some time now, is further developed through the use of micron-small vibrations in an ultrasonic frequency range within the deep-drawing tools. The design of such tools required preliminary investigations concerning the limitations of use and feasibility of this technology. These include tests for necessary clearances between punch and die, occurring pressure in this clearance, necessary punch forces and the heating of the material under the vibrational influence. According to these experiences a flexible test machine was developed enabling the examination of the deep drawing process with vibrating tools as well as its possibilities and limits. The dependence of punch force and cup quality from the ultrasonic parameters was determined and it was found that the required punch force can be reduced by up to 80% and a significant smoothing of the cup surface as well as an improved stiffness of the 3D-shapes is achieved.