https://techxplore.com/news/2025-02-ultrasonic-deep-friction-tool-lifespan.html logotype Topics * Week's top * Latest news * Unread news * Subscribe [ ] Science X Account [ ] [ ] [*] Remember me Sign In Click here to sign in with or Forget Password? Not a member? Sign up Learn more * Automotive * Business * Computer Sciences * Consumer & Gadgets * Electronics & Semiconductors * Energy & Green Tech * Engineering * Hardware * Hi Tech & Innovation * Internet * Machine learning & AI * Other * Robotics * Security * Software * Telecom [INS::INS] * * share this! * Share * Tweet * Share * Email 1. Home 2. Engineering * * * --------------------------------------------------------------------- February 20, 2025 The GIST Editors' notes This article has been reviewed according to Science X's editorial process and policies. Editors have highlighted the following attributes while ensuring the content's credibility: fact-checked proofread Ultrasonic deep drawing cuts friction by 20%, extends tool lifespan by Andreas Hemmerle, Fraunhofer-Institut fur Werkzeugmaschinen und Umformtechnik IWU Patent-worthy achievement: VibroDraw enables material-friendly ultrasonic deep drawing in series Ultrasonic deep drawing makes the difference: with a drawing ratio of 2.3 and vibration support, the deep-drawn bowl. Credit: Fraunhofer IWU You can find them in many household appliances, building technology, and countless pipe and hydraulic lines: small, cylindrical parts manufactured through deep drawing processes. The material is under strain during shaping. Potential consequences are unwanted thinning, surface damage, or cracks. The solution is ultrasonic vibrations--these reduce friction significantly within the material and in contact with the tools. In the VibroDraw process, Fraunhofer IWU, in collaboration with MARK Metallwarenfabrik GmbH and DEVAD GmbH, has successfully integrated ultrasonic vibrations into industrially relevant deep drawing processes with cycle rates of up to 500 strokes per minute. Ultrasound can reduce friction in deep drawing and thus protect tools and materials. The energy-saving potential resulting from lower forces is something manufacturers of pipes and fittings (connection materials) would also like to utilize. However, it was only the team led by M.Sc. Martin Madlow that managed to control the typical sudden stresses in industrial forming processes. Previously, effective use of ultrasound was only possible in nearly static laboratory setups. At least 20% less friction For vibration excitation, active tool parts such as the punch and die, plus the blank holder that keeps the sheet metal in the desired position during forming, are all viable. The researchers chose the die, as it has the largest share of relative movement during forming. "The die offers the most potential. We've already achieved a 20% reduction in friction, but we still see further potential," emphasizes Madlow. Regulated by the process force transmitted through the workpiece, forming usually occurs in several stages. Thanks to less friction, it is possible to deep draw much further in a single stage without damaging the material. For example, two forming steps are sufficient instead of three conventional ones. Reduced friction also means less heat input, which allows for higher stroke frequencies, and longer tool lifespans, and prevents the coking of lubricants. Patent-worthy achievement: VibroDraw enables material-friendly ultrasonic deep drawing in series With identical parameters but without ultrasonic support, the metal cracks. Credit: Fraunhofer IWU Fraunhofer IWU is advancing its activities to transfer this technology to industry swiftly. Currently, the focus is on ultrasonic deep drawing of cell housings used in high-voltage batteries for electric vehicles. The goal is larger cell formats that make better use of space and provide higher ranges thanks to increased energy density. The patent application for VibroDraw (EPA WO2025/012830 A1) has already been filed. Provided by Fraunhofer-Institut fur Werkzeugmaschinen und Umformtechnik IWU Citation: Ultrasonic deep drawing cuts friction by 20%, extends tool lifespan (2025, February 20) retrieved 9 March 2025 from https:// techxplore.com/news/ 2025-02-ultrasonic-deep-friction-tool-lifespan.html This document is subject to copyright. Apart from any fair dealing for the purpose of private study or research, no part may be reproduced without the written permission. 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This innovation enables higher stroke frequencies and less heat input, preventing lubricant coking. The technology is being applied to produce larger cell housings for electric vehicle batteries, enhancing space utilization and energy density. A patent application for this process has been filed. This summary was automatically generated using LLM. Full disclaimer Let us know if there is a problem with our content Use this form if you have come across a typo, inaccuracy or would like to send an edit request for the content on this page. For general inquiries, please use our contact form. For general feedback, use the public comments section below (please adhere to guidelines). Please select the most appropriate category to facilitate processing of your request [-- please select one -- ] [ ] [ ] [ ] [ ] [ ] Your message to the editors [ ] Your email (only if you want to be contacted back) [ ] Send Feedback Thank you for taking time to provide your feedback to the editors. 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