Production Engineering

, Volume 11, Issue 4–5, pp 455–465 | Cite as

Dynamic correction of oscillatory forces during ultrasonic-assisted metal forming

  • Markus MichalskiEmail author
  • Uwe Leicht
  • Andrew Heath
  • Marion Merklein
Production Process


Numerous investigations in the past decades reported that the forces required for forming processes can be reduced by superimposing high frequency oscillation. Even though many studies have been carried out identifying and assessing the complex cause of this reduction, cause-effect relationships are generally not yet established in detail. Since the measurement of dynamic forces plays a key role in clarifying the causes, a precise measurement of the forming forces oscillating with high frequency is necessary. Although dynamic force measurement is a well-known field of research, this study focuses on its utilisation for ultrasonic-assisted forming processes. Since dynamic effects distort original measurements in this frequency range, adjustment is required. Based on measurement instruments with high temporal resolution the present study introduces an approach for creating and employing a frequency dependent force correction in the high dynamic range. The experimental procedure for creating a transfer function up to a limiting frequency of 40 kHz is later analysed and verified by numerical modal and transient simulations. The results indicate that the highly location dependent dynamic force detection has major influence on peak forces. Observed deviations can be precisely corrected using the generated frequency dependent transfer function.


Force Measurement Metal forming Ultrasonic Transfer function Finite element method (FEM) 



This research and development project is funded by the German Federal Ministry of Education and Research (BMBF) within the Framework Concept “Research for Tomorrow’s Production” (funding number 02PN2224) and managed by the Project Management Agency Karlsruhe (PTKA). The authors are responsible for the contents of this publication.


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Copyright information

© German Academic Society for Production Engineering (WGP) 2017

Authors and Affiliations

  1. 1.Institute of Manufacturing Technology (LFT)Friedrich-Alexander-Universität Erlangen-NürnbergErlangenGermany
  2. 2.Robert Bosch GmbHRenningenGermany
  3. 3.MATFEM Partnerschaft Dr. Gese & OberhoferMunichGermany

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