Design and implementation of the ultrasonic cold forging technology process for improving surface mechanical properties of 6XB2C cold-worked alloy steel tool

Abstract

Ultrasonic cold forging technology is a mechanical process used to improve surface characteristics of materials by con-tinual striking of the tool in a reciprocating motion. In this study, the proper geometrical shapes of the booster and the horn (collectively called ‘‘the concentrator’’) were obtained through numerous simulations based on the frequencies pro-duced, the power of an ultrasonic generator (about 20 kHz), and the mechanical vibrations transferred parallel to the axis of the ultrasonic head (transducer, booster, horn, and tool). Furthermore , a pneumatic system was designed using a simulated ultrasonic cold forging technology in ord to supply the static load and to prevent tool backlash in the retract-ing motion. Post-ultrasonic cold forging technology mechanical tests revealed an improved hardness by 17% to a depth of 150 m m and an enhanced smoothness from an initial value of 0.6–0.132 mm in the compressed layers of the surface as a result of using the ultrasonic cold forging technology process.