Ultrasonically Vibrated Die Ring Radial Bending Mode
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Solution Overview
Problem
The pure radial mode (R0) of vibration in ultrasonically-assisted metal forming dies is difficult to achieve within typical space constraints, leading to inefficient energy transmission and interference with desired vibration modes, whereas the radial bending mode (RB0) offers a viable alternative but requires optimizing the mounting tube's attachment to minimize vibrational energy loss.
Innovation Solution
A die design featuring a cylindrical die ring that vibrates in a radial bending (RB0) mode, with the mounting tube attached at a radius where the amplitude of oscillation is minimal, reducing unwanted energy transmission and allowing independent vibration modes between the die ring and mounting tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the die ring is mounted firmly to withstand high forming forces, then the mechanical strength is improved, but the vibration transmission to the mounting tube increases causing energy loss
Solution Approach 1:
The mounting tube is designed with varying wall thickness along its length, creating regions of different stiffness. The thinner section acts as a vibration isolator while the thicker sections provide mechanical strength for force transmission, allowing the structure to have different local properties optimized for different functions
Solution Approach 2:
The mounting tube serves as an intermediary element between the die ring and the mounting plate. By positioning the die ring at a node of the mounting tube's vibration mode, the tube mediates the connection while minimizing vibration transmission, thus isolating the die ring's vibrational energy from being lost to the mounting structure
2Stability of the object's composition
If the die ring vibrates in pure radial mode R0, then the contact between die and workpiece is synchronous, but all points oscillate in phase preventing minimum amplitude radius for mounting tube attachment
Solution Approach 1:
The system transitions from a static mounting configuration to a dynamic one where the die ring's vibration mode is specifically selected (radial bending mode RB0) to create a time-varying amplitude distribution. This dynamic characteristic allows the mounting tube to be attached at a location that experiences minimum vibration amplitude during operation, optimizing both mounting stability and vibration isolation
3Use of energy by moving object
If the mounting tube is positioned to minimize vibrational energy loss, then the energy efficiency is improved, but the transmission of forming forces may be compromised
Solution Approach 1:
The mounting tube features non-uniform wall thickness with thinner sections positioned to isolate vibrations and thicker sections positioned to transmit forming forces effectively. This local variation in structural properties allows the same component to perform both vibration isolation and force transmission functions simultaneously
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances energy efficiency by minimizing vibrational energy loss and maintaining synchronous contact between the die's working surface and the workpiece, facilitating effective metal forming processes.
Implementation Method 1
A transducer is attached to the die ring at a location on its circumference and delivers ultrasonic energy into the die ring. The transducer vibrates along its own longitudinal axis
Implementation Method 2
The radial application of ultrasonic vibrations to the die ring induces resonant modes of vibration, depending on the shape and material of the die ring and the frequency applied
Implementation Method 3
The die ring needs to be mounted firmly enough to withstand the high forces exerted on it during the forming of a metal workpiece, while allowing it to vibrate as freely as possible at the applied frequency. It is desirable to minimize the transmission of vibrations from the die ring into the mounting tube
Data Source
AI summary
An ultrasonically vibrated die (1) comprises a generally cylindrical die ring (2) supported by a coaxial resonant mounting tube (4). The die ring (2) is vibrated in a radial bending (RB0) mode of vibration, in which an end surface (5) of the die ring (2) oscillates between a concave and a convex state. The mounting tube (4) joins the end surface (5) of the die ring (2) at a radius R where the amplitude of the oscillation of the end surface (5) is at a minimum, in order to reduce transmission of the vibration into the mounting tube (4).