Micro extrusion is an economically competitive process to fabricate micro metallic parts. However, fabrication of extremely small geometric features leads to challenges in tool wear due to localized high stress and friction increase at the interface. This study focuses on micro pin extrusion of aluminum with assistance of ultrasonic vibration. Experiments were conducted with and without ultrasound using magnetostrictive actuator. Load-displacement curves from the experiments showed a load reduction when ultrasonic vibration was applied. Experiments of ultrasonic micro pin extrusion with two configurations were performed. The load reduction behaviors at off-resonance and in-resonance conditions were compared. The reduction can be explained by stress superposition of ultrasonic vibration.
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