Plastic deformation of magnesium alloy with different forming parameters during ultrasonic vibration-assisted single-point incremental forming

The research of forming parameters on the ultrasonic vibration single-point incremental forming of magnesium alloy plastic deformation can provide a theoretical basis for the establishment of the forming parameters. According to the forming characteristics of magnesium alloy sheet, a new method of ultrasonic vibration-assisted single-point incremental forming was proposed. The influence of forming parameters on the plastic deformation of magnesium alloy was studied by finite element simulation and experimentation. The influence of vibration frequency, amplitude, friction coefficient, and tool head size on stress and thinning rate of magnesium alloy during ultrasonic vibration-assisted single-point asymptotic forming was studied. The results show that the vibration frequency of 20 kHz and forming tool radius of about 5 mm are beneficial for plastic deformation magnesium alloy in ultrasonic vibration-assisted single-point incremental forming. With vibration amplitude increasing, the maximum shear stress tends to decrease as a whole, but at the amplitude of 0.16 mm, the thinning rate is large and fracture occurs easily. With friction coefficient increasing, the maximum shear stress tends to increase, and there is a good linear relationship between the maximum thinning rate and the friction coefficient.