Ultrasonic excitation of segmented dies

A method for reducing areas of friction within a forming die, comprising:

• (a) providing a forming die, wherein the forming die is adapted for use in sheet metal forming processes, and wherein the forming die includes surfaces that contact sheet metal being formed by the forming die;
• (b) identifying at least one region of friction between the surfaces of the forming die and the sheet metal being formed by the forming die;
• (c) designing a die segment corresponding to the at least one region of friction, wherein the designed die segment includes at least one ultrasonic transducer embedded completely within the die segment, and wherein the at least one ultrasonic transducer is surrounded on all sides by the material of the designed die segment;
• (d) modifying the forming die to receive the designed die segment that includes the at least one ultrasonic transducer embedded completely within the designed die segment;
• (e) installing the designed die segment in the forming die and acoustically isolating the designed die segment from the remainder of the forming die;
• and
• (f) creating a three-dimensional, ultrasonically vibrating, acoustically resonating die segment by energizing the at least one ultrasonic transducer to provide ultrasonic energy to the installed designed die segment, wherein providing ultrasonic energy to the installed designed die segment reduces friction between the surfaces of the forming die and the sheet metal being formed by the forming die.