Ultrasonic Assisted Microextrusion and Microtube Hydroforming

该奖项的研究目标是研究超声辅助微成形的机理，重点是微挤压和微管液压成形。微成形技术是一种小型化技术，具有很大的潜力，高生产率。由于零件的复杂性、低材料成形性、不均匀性、严重的摩擦学条件和其他尺寸效应而不能进行微成形的微型零件，通过超声辅助微成形成功地生产具有很大的潜力。在这项研究中，超声波振动对材料流动特性，材料的可成形性和摩擦学条件的影响将通过分析建模，数值模拟和实验研究。将建立用于预测由超声波振动引起的温度产生的分析模型，再加上由于塑性变形引起的温度。通过实验，将研究由于不同能量水平的超声振动引起的温度升高而引起的材料特性的转变。超声波能量对工具-工件界面处的润滑剂化学品的反应响应的影响也将被研究，最终目标是确定用于该过程的合适且有效的润滑剂化学品。 如果成功的话，从这项研究中建立的基本原理将被用来建立一个知识库，通过超声辅助微成形开发具有成本效益的3D微型零件制造方法。从这项研究中获得的知识可能会导致新的温微成形工艺技术，其中坯料加热是通过超声振动引起的热能来实现的。本研究对微型零件制造商和大规模生产空心和实心微型零件的微成形机系统开发具有重要价值。由于对微型零件的高需求，生物医学、电子、军械和通信行业预计将受益于这项技术。研究结果将纳入制造课程，并通过研讨会、会议和期刊文章传播。研究生和本科工程专业的学生将受益于课堂教学和参与研究。

The research objective of this award is to study the mechanics of ultrasonic assisted microforming, focusing on micro-extrusions and microtube hydroforming. Microforming is one of the miniaturization technologies with great potential for high production rates. There is great potential for miniature parts that cannot be microformed due to part complexity, low material formability, inhomogenuity, severe tribological conditions and other size effects, to be successfully produced by ultrasonic assisted microforming. In this research, the influence of ultrasonic vibrations on material flow characteristics, material formability, and tribological conditions will be studied through analytical modeling, numerical, and experimentation. Analytical models for predicting temperature generation caused by ultrasonic vibrations, coupled with temperature induced due to plastic deformation will be established. Through experimentation, the transformation of material characteristics due to temperature rise caused by ultrasonic vibrations at different energy levels will be studied. The effect of ultrasonic energy on the reaction response of lubricant chemicals at the tool-workpiece interface will also be studied with an ultimate goal of identifying suitable and effective lubricant chemicals for this process. If successful, the fundamentals established from this study will be used to build a knowledge-base for developing cost-effective manufacturing method for 3D-miniature parts via ultrasonic assisted microforming. The knowledge gained from this research may lead to novel warm microforming process techniques, where billet heating is achieved through the heat energy induced from ultrasonic vibrations. This research will be of significant value to manufacturers of miniature parts and developers of microforming machine systems for mass production of hollow and solid micro parts. Biomedical, electronics, ordnance, and communication industries are expected to benefit from this technology due to high demand of miniature parts. Research findings will be incorporated into manufacturing courses and dissemination through seminars, conferences and journal articles. Graduate and undergraduate engineering students will benefit through classroom instruction and involvement in the research.