DESIGN OF ULTRASONIC COMPACTION TOOL FOR POWDER METALLURGY

The current study is presented into the investigation of the application of ultrasonic vibration on the lower punch during compaction process of powder metallurgy material. The lower punch is specifically designed of ultrasonic horn which has been tuned at frequency of 20 kHz and vibrates in longitudinal mode. Finite Element modeling was used to assist the design process of the lower punch or horn. The horn was fabricated using high grade aluminium alloy and mounted onto the ultrasonic system test rig and subsequently tested prior the experimental process begins. Various static and ultrasonic compaction procedures have been carried out to confirm the capability of the tool to operate. The compaction force was reduced significantly at the onset of ultrasonic vibration applied compared to without ultrasonic.