Influences of Process Parameters and Vibration Parameters on the Forming Force in the Ultrasonic-Assisted Incremental Forming Process

In the field of plastic forming, ultrasonic vibration has the advantages of small forming force and high forming quality, and it has been introduced into a single-point incremental plastic forming technique with high flexibility and high precision. The ultrasonic vibration single-point incremental compound forming technology with all the above advantages has been achieved. To reveal the variation tendency of the forming force under ultrasonic vibration and single-point incremental coupling, the process parameters (layer spacing, tool head radius, and feed rate) and vibration parameters (frequency and amplitude) on the forming force of the composite technology were quantitatively analyzed by theory, simulation, and experiment. The simulation and experimental results showed that ultrasonic vibration can significantly reduce the forming force of the composite technology. Compared with the simulation results, the theoretical results are not only closer to the experimental results but also have a shorter computation time and better prediction effect on the forming force. The change in the process parameters has a linear effect on the forming force, the nonlinearity of the vibratory parameters influences the forming force, and the frequencies and amplitudes in a suitable range allow the forming force to reach a minimum value. These conclusions have some significance for further studies on the ultrasonic vibratory single-point incremental composite forming technology