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TECHNICAL PAPERS

Superimposing Ultrasonic Waves on the Dies in Tube and Wire Drawing

[+] Author and Article Information
Klaus Siegert, Jochen Ulmer

Institute for Metal Forming Technology, University of Stuttgart, Stuttgart, Germany

J. Eng. Mater. Technol 123(4), 517-523 (Jul 24, 2001) (7 pages) doi:10.1115/1.1397779 History: Received July 24, 2001
Copyright © 2001 by ASME
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References

Figures

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Die mounting and oscillation system 17
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Relative force reduction versus US-amplitude for three different strains, drawing velocity: 13,2 mm/s, lubrication: boric anhydride, material: stainless steel, die: hard alloy die shrunk in a half-wavelength-oscillator 17
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Surface roughness versus drawing velocity for two different strains, US-amplitude 10 μm, lubrication: boric anhydride, material: stainless steel, die: hard alloy die shrunk in a half-wavelength-oscillator 17
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Wire-drawing experiment
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Wire-drawing experiment, assumption, PKD-die, drawing velocity: 340 mm/s, wire material: Ti-alloy, lubricant: mineral oil without additives, viscosity at 40°C: 50*10−6 m2/s, quantity of lubricant: 1 g/m2 , ultrasonic power: 150–250 W
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Three-dimensional Abbott-curves calculated out of stripe-projection measurements. PKD-die, drawing velocity: 340 mm/s, wire material: Ti-alloy, lubricant: mineral oil without additives, viscosity at 40°C: 50*10−6 m2/s, quantity of 100–250 W.
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Cu-alloy surfaces without (left) and with acoustic vibration (right)
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Comparison between experimental results and theoretical predictions of the drawing force with the upgraded Siebel-Theory for the ultrasonic wire-drawing experiment
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Excitation principles in ultrasonic tube-drawing
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Reduction of the drawing force with ultrasonic vibration 21. Copper Cu58, drawing velocity 340 mm/s, ultrasonic frequency 22 kHz, ultrasonic amplitude 13 μm, lubricant mineral oil without additives, viscosity at 40°C: 300*10−6 m2/s.
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Inner surface of a tube without (upper) and with ultrasonic vibrations (lower) 21, copper Cu58, drawing velocity 340 mm/s, ultrasonic frequency 22 kHz, ultrasonic amplitude 13 μm, lubricant mineral oil without additives, viscosity at 40°C: 300*10−6 m2/s
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Forming parts (upper) and friction parts (lower) influencing the drawing force 21
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Comparison of the experimental and theoretical drawing force with and without ultrasonic vibration 21. Copper Cu58, drawing velocity 5 mm/s, ultrasonic frequency 21,6 kHz, ultrasonic amplitude 13 μm, lubricant mineral oil without additives, viscosity at 40°C: 300*10−6 m2/s,φg=0,2, μ=0,07, diameter of the mandrel 20,7 mm, workpiece 25×2 mm, drawing angle 2α=16 deg.
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Typical data plots. A: friction force without ultrasonic vibration with constant drawing velocity. B: friction force with ultrasonic vibration, with constant drawing velocity, quantity of lubricant 1,0g/mm2 , lubricant mineral oil, workpiece AK-Steel, die 1.2379.
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Friction force reduction versus drawing velocity and normal load at three different ultrasonic amplitudes, quantity of lubricant 1,0 g/mm2 , lubricant mineral oil, workpiece AK-Steel, die 1.2379
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Friction coefficient versus drawing velocity with and without superimposed ultrasonic vibrations, die material: 1.2379, sheet material: AK-steel, lubricant: mineral oil without additives, viscosity at 40°C: 10, 50, 100, 200*10−6 m2/s, quantity of lubricant: 1 g/m2 , normal force: 433 N, ultrasonic power: 570 W 24
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Surface-scan, drawing velocity: 200 mm/s, die material: 1.2379, sheet material: AK-steel, lubricant: mineral oil without additives, viscosity at 40°C: 50*10−6 m2/s, quantity of lubricant: 1 g/m2 , normal force: 433 N, ultrasonic power: 570 W
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Abbott curves with and without the influence of ultrasound, drawing velocity: 200 mm/s, die material: 1.2379, sheet material: AK-steel, lubricant: mineral oil without additives, viscosity at 40°C: 50*10−6 m2/s, quantity of lubricant: 1 g/m2 , normal force: 433 N, ultrasonic power: 570 W

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