Predictive assessment of the ultrasonic shearing quality of AZ31B magnesium alloy sheet based on coupled vibration-thermal model

Poor-quality sheet sections and excessive burrs may be resolved by incorporating ultrasonic vibration into the shearing process of hard-to-deform magnesium alloy sheets. It is challenging to simulate the complicated mechanical process of ultrasonic shearing process because it involves material deterioration and fracture, elastic–plastic deformation of the material, and the impacts of ultrasonic indirect sexual contact. Relying on ABAQUS/Explicit finite element simulation software, this paper for the first time proposes a boundary constraint method of constructing a converter to connect displacement reference points and vibration reference points in order to perform numerical simulation of the ultrasonic shearing process of AZ31B magnesium alloy. The team’s ultrasonic vibration system serves as the basis for the simulation’s shearing model. This model utilizes three variables, namely sheet temperature, shear edge clearance, and ultrasonic amplitude, to analyze the weight coefficients and the influence law on the equivalent stress using the orthogonal test in order to further characterize the processing characteristics of ultrasonic shearing. This research demonstrates that numerical simulation is an effective method for examining the influence of process parameters on stress distribution. The results showed that in the ultrasonic shearing of AZ31B magnesium alloy sheet, the process parameter with the greatest influence on the weight coefficient was the sheet temperature, which was 49.8667, followed by the shear edge clearance, which was 31.2667, and the ultrasonic amplitude, which was 17.5333. When the sheet temperature is 150 ℃, the optimization effect is maximal, and the equivalent stress is reduced by 63.9 MPa. Under identical conditions, ultrasonic shearing substantially reduces the equivalent stress on the sheet compared to conventional shearing. During the ultrasonic shearing procedure, the equivalent stress of the sheet appears to be stress superposition and stress fluctuation, resulting in a significant improvement in sheet section quality. As a result, the paper can serve as a quantitative guide for predicting the ultrasonic shearing quality of the AZ31B magnesium alloy sheet.