GOALI/Collaborative Research: Improving Incremental Sheet Forming by Ultrasonically Enhanced Material Deformation

GOALI/合作研究：通过超声波增强材料变形改进增量板材成型

• 批准号: 2018963
• 负责人: Alan Taub
• 金额: $ 30万
• 依托单位: Regents of the University of Michigan - Ann Arbor
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2020
• 资助国家: 美国
• 起止时间: 2020-09-01 至 2024-02-29
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2018963&HistoricalAwards=false
• 关键词: GOALI; Collaborative; Research; Improving; Incremental

This Grant Opportunity for Academic Liaison with Industry (GOALI) award supports research that contributes to the understanding of ultrasonically-enhanced incremental sheet forming with funding from the Advanced Manufacturing Program in the Civil, Mechanical, and Manufacturing Innovation Division and from the Metals and Metallic Nanostructures Program in the Division of Materials Research. Despite the rapid development of ultra-high strength materials, their readiness to use is limited by limitations in the associated manufacturing processes, especially in the field of sheet metal forming. One promising solution is to temporarily soften the material during the forming process, which can be achieved with the assistance of ultrasonic energy. However, the underlying principles of this softening phenomenon remain elusive. Another benefit of applying ultrasonic energy is improved tribological behavior. Among forming technologies, incremental sheet forming is advantageous in rapid prototyping based on its universal tooling and high flexibility, which meet the increasingly competitive market demands of product updates and customization. However, achieving high geometric accuracy and surface finish quality are challenging. In this aspect, both the ultrasonic softening and modified friction can be harnessed as a unique process and property enhancement solution. The fundamental research of ultrasonic effects on material behavior facilitates effective incorporation of ultrasonic energy into incremental sheet forming, which greatly benefits sheet metal applications in industries such as aerospace, automotive and biomedical. Students involved in the project gain multidisciplinary knowledge and research experiences in materials, mechanical engineering and manufacturing. Students, particularly women and underrepresented minorities, have the opportunity to interact with GOALI partner Boeing engineers.This project aims to advance the fundamental knowledge of ultrasonic softening mechanisms on material deformation behavior. The research is to effectively utilize ultrasonic energy to enhance the incremental sheet forming (ISF) process based on both its bulk softening and modified surface tribological behavior. First, an innovative ultrasonically assisted (UA) micro-tensile testbed, equipped with an in situ high speed optical microscope imaging system, is developed. This enables digital image correlation analysis on the transient inter and intragranular strain field within the ultrasonic vibration cycle. Post mortem multiscale microstructure characterizations are then performed. A dislocation density-based crystal plasticity constitutive material model is developed to reveal the physical principles that are beyond experimental observations. Second, the UA-ISF process is comprehensively studied, in which relationships between the reduced forming force, increased forming accuracy, improved surface finish and the ISF and ultrasonic parameters are established. Finally, a coupled acousto-mechanical process model for UA-ISF is developed, which incorporates the ultrasonically affected material constitutive model developed in the first task. With experimental validations, this model would be utilized to optimize UA-ISF in forming parts with complex free-form geometries.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

这项学术与工业联系机会(GOALI)奖支持有助于理解超声增强板材增量成形的研究，资金来自土木、机械和制造创新部的先进制造计划和材料研究部的金属和金属纳米结构计划。尽管超高强度材料发展迅速，但它们的使用受到相关制造工艺的限制，特别是在板材成形领域。一个有希望的解决方案是在成形过程中暂时软化材料，这可以在超声波能量的帮助下实现。然而，这种软化现象的根本原则仍然难以捉摸。应用超声波能量的另一个好处是改善了摩擦学行为。在众多的成形技术中，板材渐进成形以其通用的模具和高度的柔性，在快速成形方面具有优势，满足了竞争日益激烈的产品更新换代和定制化的市场需求。然而，实现高几何精度和表面光洁度是具有挑战性的。在这方面，超声波软化和改性摩擦都可以作为一种独特的工艺和性能增强方案来利用。超声波对材料行为影响的基础研究有助于将超声波能量有效地结合到板材增量成形中，从而极大地促进了板材在航空航天、汽车和生物医学等行业的应用。参与该项目的学生获得了材料、机械工程和制造方面的多学科知识和研究经验。学生，特别是女性和代表性不足的少数民族，有机会与目标合作伙伴波音工程师互动。该项目旨在促进材料变形行为的超声波软化机理的基础知识。本研究旨在有效地利用超声波能量强化板材渐进成形(ISF)过程，以改善ISF的整体软化和表面摩擦学行为。首先，研制了一种新型超声辅助(UA)微拉伸试验台，该试验台配备了高速光学显微镜原位成像系统。这使得能够对超声振动周期内的瞬时晶间应变场和晶内应变场进行数字图像相关分析。然后进行了死后多尺度显微结构表征。发展了一种基于位错密度的晶体塑性本构材料模型，以揭示实验观测不到的物理原理。其次，对UA-ISF工艺进行了全面的研究，建立了降低成形力、提高成形精度、改善表面质量与ISF和超声参数之间的关系。最后，结合第一个课题中建立的超声作用下的材料本构模型，建立了超声速ISF的声力学耦合过程模型。通过实验验证，该模型将用于优化UA-ISF成形复杂自由形状几何形状的零件。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势和更广泛的影响审查标准进行评估，被认为值得支持。

项目成果

Prediction of Forming Forces for Incremental Micro-Forming Using Finite Element Analysis

• DOI: 10.4028/p-n18b9s
• 发表时间: 2022-07
• 期刊: Key Engineering Materials
• 作者: A. Bansal;Randy Cheng;M. Banu;A. Taub;J. Ni

Acoustic softening – Investigation of the volume effect and introduction of amplitude strain parameter

• DOI: 10.1016/j.msea.2023.145437
• 发表时间: 2023-07
• 期刊: Materials Science and Engineering: A
• 作者: Randy Cheng;S. Rose;A. Taub

Applying ultrasonic vibration during single-point and two-point incremental sheet forming

• DOI: 10.1016/j.promfg.2019.06.137
• 发表时间: 2019
• 期刊: Procedia Manufacturing
• 作者: Randy Cheng;N. Wiley;M. Short;Xun Liu;A. Taub