Iranian Journal of Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Finite element analysis of the axial vibration effect on forging process

Document Type : Original Article

Authors
Mehdi Jafari Vardanjani
Yaghoub Dadgar Asl
Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran
10.22034/ijme.2025.522512.2079
Abstract
Vibration-assisted forming has emerged as an innovative technique in metalworking industries, where applied mechanical vibrations during forming processes significantly reduce required forces while improving product quality. This method operates through two fundamental mechanisms: firstly, the bulk effect, which lowers yield stress by influencing dislocation movement and reducing crystalline defect density; secondly, the surface effect that diminishes the effective friction coefficient through periodic contact reduction between surfaces. In this study, the Slice analytical method has been employed through finite element simulations to examine how sinusoidal versus triangular waveform vibrations affect viscoplastic forming conditions. The results demonstrate that triangular waveforms provide superior force reduction compared to sinusoidal vibrations. Furthermore, the vibration-to-die speed ratio was identified as a critical parameter determining the magnitude of forming force reduction. Increasing the amplitude from 12 to 24 μm reduced the forging force by 18%, while raising the frequency from 40 to 80 Hz resulted in a 7% decrease.The results, with less than 1.2% error compared to experimental data, confirm the model's accuracy within accepted engineering standards. These findings have established a robust foundation for optimizing industrial metal forming processes through vibration implementation, potentially revolutionizing energy-efficient manufacturing approaches.
Keywords
Vibrational Forming
Visco-Plasticity
Finite Element Analysis
Theoretical Equations
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