Within this work an experimental set-up was designed and constructed. It allows axial vibrations application to replaceable punches with a frequency of 20 kHz. Specially designed sonotrode allows amplification of the vibration amplitude of the piezoelectric vibrator. An unique power system allows smooth reduction of maximal amplitude within two ranges of peak to peak amplitude: 1-8 um and 30-50 um. The ultrasonic system is mounted on precision testing machine. Processes of micro-upsetting of cylindrical aluminum 1x1 mm samples were carried out in a special miro-die set. The methodology has been developed to prevent the swelling specimens from the forming area and the method of indirect amplitude control on the punching face. A 40% reduction in process power was observed with a doubling of vibration amplitude. A mechanism has been observed for the creation of multiple parallel fracture surfaces that have merged during the process so that the samples did not lose cohesion. This phenomenon was not reflected in the course of process forces. It was only possible during the structural analysis.Keywords: Microforming, Ultrasonic-assisted, micro-upsetting
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