Ultrasonic-vibration upsetting is a process in which a cylindrical specimen is compressed by an axial force while the ultrasonic vibration is simultaneously applied to the die. Homogenous deformation is difficult to achieve during this process because of the friction at the interface between the specimen and the die. An extrapolated compression test was performed in this study on aluminum alloy specimens to explore the effect of superimposing ultrasonic-vibration during upsetting. Experimental results indicate that ultrasonic-vibration reduced the compressive force when the friction was eliminated by the extrapolated compression test. The specimen size also influences the force-reducing effects of ultrasonic-vibration. The decrease in the compressive force is smaller for a larger specimen. The barreling profile of the specimen after test indicates that the interface friction will increase during ultrasonic-vibration compression. Additionally, the raised material temperatures are caused by ultrasonic-vibration. Experimental results of the hot extrapolated compression test and the hot ring compression test indicate that the drop in the flow stress and the increase in the interface friction are caused by the increase in the temperature of the material under ultrasonic vibration.

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