Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

Ultrasonic-assisted forming and caulking within the joint research project “UltraCaulk” – development of the fundamentals and the simulation model

Project Status: finished


Objective of the research project "UltraCaulk" was the development of a hybrid manufacturing process for the ultrasonic-assisted forming of difficult-to-deform materials, such as high strength steel. The superimposed oscillation enables a considerable reduction of the required forces and therefore the workpiece loading. The sub-project "development of the fundamentals and the simulation model" was mainly concerned with the identification of relevant process parameters and potential causes for the force reduction occurring during ultrasonic-assisted compression testing with different metallic materials. For stainless steel X17CrNi16-2 an amplitude dependent force reduction of up to 43 % is generated, which could be traced back to thermal and microstructural influences.

Force reduction and specimen heating during ultrasonic-assisted (US) compression testing

Research Groups



    • Michalski, M.; Lechner, M.; Gruber, M.; Merklein, M.:
      Influence of ultrasonic vibration on the shear formability of metallic materials.
      CIRP Annals - Manufacturing Technology 67(2018)1, pp. 277-280


    • Leicht, U.; Michalski, M.; Merklein, M.:
      Ultraschallunterstütztes Umformen und Verstemmen - Aktuelle Ergebnisse aus dem Verbundprojekt "UltraCaulk".
      wt Werkstattstechnik online 107(2017)H. 1/2, pp. 52-58

    • Michalski, M.; Piott, F.; Merklein, M.:
      Compression testing of martensitic stainless steel with superimposed ultrasonic vibration.
      Procedia Engineering 207(2017), pp. 1970-1975

    • Michalski, M.; Leicht, U.; Heath, A.; Merklein, M.:
      Dynamic correction of oscillatory forces during ultrasonic-assisted metal forming.
      Production Engineering 11(2017)4-5, pp. 455-465


    • Michalski, M.; Merklein, M.:
      Ultrasonic-Assisted Upsetting of Steel with 15 kHz Oscillation Frequency.
      Key Eng. Mater. 716(2016), pp. 544-551


    • Michalski, M.; Leicht, U.; Engler, S.; Merklein, M.:
      Tool System for Ultrasonic-Assisted Forming and Material Characterisation with 15 kHz Oscillation Frequency.
      Appl. Mech. Mater. 794(2015), pp. 427-434

    • Michalski, M.; Merklein, M.:
      Ultraschallunterstützte Umformung von Metallen - Entwicklung eines Prüfstands zur Werkstoffcharakterisierung mit 15 kHz Schwingungsüberlagerung.
      wt Werkstattstechnik online 105(2015)H. 10, pp. 715-721

    Letztes Update: 21.02.2018