Finite element modelling in ultrasonic sheet metal forming

Finite element (FE) model of die necking process of an aluminium hollow thin cylinder has been developed. The input parameters of material properties and coefficient of friction, µ for the model have been deducted from our previous experimental study. Later the models have been validated against experimental data as reported in the previous studies. For the die necking process, the FE model has successfully to predict how much the original diameter of the aluminium hollow cylinder can be maximised necked with and without applying ultrasonic vibration. FE models showed that the application of ultrasonic vibration during the necking process has reduced buckling of the cylinder body if compared to the necking process without ultrasonic. The benefit of applying ultrasonic vibration in sheet metal forming process has been related to the reduction of interface friction between die and specimen