Hydrostatic support and ultrasound-assisted SPIF error and process parameter optimization study

Abstract

To solve the problems of overhanging back of the part and difficult forming and to improve the accuracy of single-point incrementally formed parts, considering many error influencing factors, this paper introduces hydrostatic support and ultrasonic vibration-assisted technology into single-point incremental forming and investigates the influence of process parameters on the geometric shape error of formed parts under the conditions of hydrostatic support and ultrasonic vibration, taking the conical table part as the object. A four-factor, three-level process experiment with static pressure, amplitude, frequency, and tool head diameter as variables was designed using Box-Behnken Design, modeled by the least squares method in the response surface method, and optimized by the satisfaction function. The results show that the static pressure support and ultrasonic vibration can effectively reduce the error of the part, and the error is minimized when the static pressure value is 0.058 MPa, the amplitude is 0.019 mm, the vibration frequency is 25 KHz, and the tool head diameter is 15.7 mm. The method and conclusions presented in this paper can provide a reference for the study of single-point increments of hydrostatic support-ultrasonic vibration.