多模式超声振动辅助微成形特性及形性预测模型

doi:10.3901/JME.260544

机械工程学报 ›› 2026, Vol. 62 ›› Issue (14): 178-187.doi: 10.3901/JME.260544

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多模式超声振动辅助微成形特性及形性预测模型

万炜强^1,2, 韩光超^2,3, 胡济涛², 刘富初^2,3

1. 河南工业大学机电工程学院郑州 450001;
2. 中国地质大学(武汉)机械与电子信息学院武汉 430074;
3. 中国地质大学深圳研究院深圳 518057

收稿日期:2025-09-09 修回日期:2026-01-15 发布日期:2026-08-29
作者简介:万炜强，男，1993年出生，博士，讲师。主要研究方向为超声辅助微塑性加工工艺及机理。E-mail：wanweiqiang@cug.edu.cn;韩光超(通信作者)，男，1974年出生，博士，教授，博士研究生导师。主要研究方向为超声辅助微塑性成形及超声辅助切削加工工艺。E-mail：hgc009@cug.edu.cn
基金资助:
国家重点研发计划(2022YFB4602502，2023YFB4605603)、深圳市基础研究面上(JCYJ20240813114009013)、河南省科技攻关(262102220046)和河南省超硬磨料磨削装备重点实验室开放课题(JDKFJJ2025003)资助项目。

Multi-mode Ultrasonic Vibration Assisted Microforming

WAN Weiqiang^1,2, HAN Guangchao^2,3, HU Jitao², LIU Fuchu^2,3

1. School of Mechanical and Electrical Engineering, Henan University of Technology, Zhengzhou 450001;
2. School of Mechanical Engineering & Electronic Information, China University of Geosciences, Wuhan 430074;
3. Shenzhen Research Institute, China University of Geosciences, Shenzhen 518057

Received:2025-09-09 Revised:2026-01-15 Published:2026-08-29

摘要/Abstract

摘要： 超声振动辅助微成形技术凭其降低成形载荷、提升微腔充填能力及改善表面质量的优势，已成为微型构件精密成形的重要工艺之一。针对微轴类零件挤压成形过程中易出现的充填不足与质量缺陷问题，系统研究了多模式超声振动对T2纯铜不同方向微挤压成形行为的影响机理。通过定量表征成形应力、充填能力、微观组织演变等关键指标，揭示了超声振动模式与挤压成形方向对材料微塑性变形行为的耦合作用机制。基于此，建立了超声振动模式与挤压成形方向的应力耦合理论模型，以定量描述成形应力的衰减规律。进一步建立了基于遗传算法优化的神经网络预测模型，其平均相对误差为1.03%，实现了不同超声参数及工艺条件下材料充填能力的高精度预测，为微型构件形性协同优化提供了有效支撑。相关研究结果为超声能场在微纳制造领域的应用与优化提供了重要理论依据和技术支撑。

关键词: 多模式超声振动, 微塑性成形, 挤压成形方向, 成形机理, 形性预测

Abstract: Ultrasonic vibration-assisted microforming has become an important technique for fabricating micro-components owing to its ability to reduce forming load, enhance microcavity filling, and improve surface quality. To address insufficient filling and quality defects in the micro-extrusion of micro-shaft components, the effects of multi-mode ultrasonic vibration on the micro-extrusion behavior of T2 copper under different forming directions were systematically investigated. By quantitatively characterizing forming stress, filling capability, and microstructural evolution, the coupled mechanisms between vibration modes and extrusion directions in microplastic deformation were clarified. On this basis, a coupled theoretical model was developed to describe the attenuation behavior of forming stress. Furthermore, a genetic algorithm-optimized neural network model was established, achieving an average relative prediction error of 1.03%, to predict material filling performance under various ultrasonic parameters and process conditions, thereby supporting the synergistic optimization of shape and properties of micro-components. The results provide theoretical insights and practical guidance for micro- and nano-manufacturing.

Key words: multi-mode ultrasonic vibration, micro plastic forming, extrusion forming direction, forming mechanism, shape-property prediction

中图分类号:

TG371

万炜强, 韩光超, 胡济涛, 刘富初. 多模式超声振动辅助微成形特性及形性预测模型[J]. 机械工程学报, 2026, 62(14): 178-187.

WAN Weiqiang, HAN Guangchao, HU Jitao, LIU Fuchu. Multi-mode Ultrasonic Vibration Assisted Microforming[J]. Journal of Mechanical Engineering, 2026, 62(14): 178-187.

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http://www.cjmenet.com.cn/CN/Y2026/V62/I14/178

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多模式超声振动辅助微成形特性及形性预测模型

Multi-mode Ultrasonic Vibration Assisted Microforming

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