Iranian Journal of Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Experimental comparison of the forming limit diagram in hot incremental forming and ultrasonic vibration assisted hot incremental forming on Ti-6AL-4V alloy

Document Type : Original Article

Authors
Mehdi Jafari Vardanjani
Saeed Amini
Department of Mechanical Engineering, National University of Skills (NUS), Tehran, Iran
10.22034/ijme.2025.477192.2005
Abstract
Electric hot incremental forming (EHIF) technique is a novel sheet metal forming method for low formability materials like Mg and Ti-6Al-4V alloys. There are some defects in EHIF including low surface quality, unexpected sheet tear and oxidation of the fabricated workpieces. These defects limit its widespread use. In this paper, longitudinal ultrasonic vibrations (UV) of forming tool are used for Ti-6Al-4V sheets in the EHIF process. This technique led to a significant reduction of friction coefficient and improvement of workpieces surface quality. Also, combination of mechanical vibrations and heat reduced the phase transformation temperature of a phase (HCP structure) to the more formable β phase (BBC structure) at 600 ° C. It improved Ti-6Al-4V sheets formability. In this study, various tensile and compressive strains were created by manufacturing different geometries such as cone, frustum, torespherical, and five-lobe. These strains are used to compare the Forming Limit Diagram (FLD) of the ultrasonic-assisted and conventional hot incremental forming. Design of experiment and analysis of variance (ANOVA) were employed to identify the optimum condition for creating the largest strains. Also, effective parameters were optimized by Response Surface Methodology (RSM). Then major and minor strains for both techniques were compared. Achieved strains in all types of geometries for ultrasonic-assisted technique were about 25% higher than those achieved by conventional process.
Keywords
Hot Incremental Forming
Ultrasonic
Forming Limit Diagram
Ti-6Al-4V
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