The application of vibration analysis techniques to the development of an ultrasonically assisted die forming process

One of the requirements for significant cost savings in the manufacture of tinplate cans in the packaging industry, is to achieve a die formed diameter reduction (or neck) on the can, inexpensively and reliably. A novel technique for the formation of a neck on metal canisters, uses the ability of ultrasonic vibration to reduce the apparent friction (and hence forming force) between the die work surface and the material being formed. Ultrasonic forming, although known to be a viable technique, has not been fully exploited due to a lack of understanding of the process. This has resulted in a lack of tool design knowledge and process reliability problems. The aim of the research reported in this thesis, is to investigate the vibration characteristics of ultrasonically excited forming tools with reference to the metal forming process and particularly, from a tool design viewpoint. [Continues.]