Ultrasonic vibration-assisted single point incremental forming of hemispherical shape using multi-stage forming strategy

Ultrasonic vibrations have found widespread engineering applications. The use of ultrasonic vibrations in machining and welding processes have reached the commercially viable stage. However, the application of ultrasonic vibrations in sheet metal forming applications is still in the research phase. This paper addresses the application of ultrasonic vibrations in a single point incremental forming process. The main focus of the paper is on the development of the ultrasonic vibration-assisted forming set-up customised to the vertical machining centre (VMC). Experiments have also been conducted with the developed set-up to produce the hemispherical shape which is difficult to form using a single-stage strategy using the single point incremental forming process. A multi-stage forming strategy has been used to form the hemispherical shape and the analysis of the results has been presented.