The Mechanism Study On Ultrasonic Vibration-assisted Blanking Of 6061 Aluminum Alloy

Vibration plastic processing is a technique in which the vibration with certain frequency and certain amplitude is acted on the processed material or processing tools from given direction.This method could reduce the forming force,improve the formability of processed material and ameliorate the quality and dimensional accuracy of final products.It provides a new technology for the plastic forming process to expand the range of processed object.In this paper,the vibration blanking process was researched for 6061 aluminum alloy which is a kind of heat-treatable light alloys.Applying supersonic vibration to the blanking process for 6061 aluminum alloy,the effect of technological parameters on blanking process was investigated in a vibrating environment.Combining the macroscopic and microcosmic methods,the deformation mechanism of vibration blanking for 6061 aluminum alloy sheet was studied using the existing theory of blanking and vibration forming.The special working was as follows1)Experimental devices were designed and manufactured for material performance testing,friction coefficient testing and blanking test,and modal analysis was conducted for the critical components of devices.2)Under the condition of vibration,the mechanical property of 6061 aluminum alloy is researched and its constitutive model was created using the volume effect theory.3)Based on the constitutive model obtained under the condition of vibration,a numerical simulation model was created to analyze the blanking process.4)An experimental study under the condition of vibration was performed on 6061 aluminum alloy to research the effect of blanking clearance and amplitude on blanking process and result,such as blanking curve and fracture surface.Microcosmic analysis was conducted on the experimental parts to study the influence of volume effect on blanking process.The experimental results were also compared with numerical simulation results.The studying results showed that the material constitutive model was changed and a soften phenomenon appeared when the vibration was acted on the forming process.Analyzing results using the volume effect theory indicated that the significant factor for forming process was amplitude.The friction test showed that the vibration could reduce the friction force which was consistent with the surface effect theory.In addition,the vibration had a big influence on the blanking result.It decreased the blanking force and improved the quality of fracture surface obviously.However,blanking clearance had little influence on the blanking result.