Progressive microforming process : towards the mass production of micro-parts using sheet metal

Although there is considerable published literature on micro-metal forming processes, there is still a lack of research towards implementing these processes commercially. Some of the challenges are handling of micro-parts and process intermittency. This work demonstrates the feasibility of producing...

Full description

Saved in:
Bibliographic Details
Main Authors: Jarfors, Anders E. W., Ghassemali, Ehsan, Tan, Ming-Jen, Lim, Samuel Chao Voon
Other Authors: School of Mechanical and Aerospace Engineering
Format: Article
Language:English
Published: 2013
Online Access:https://hdl.handle.net/10356/100219
http://hdl.handle.net/10220/13585
Tags: Add Tag
No Tags, Be the first to tag this record!
Institution: Nanyang Technological University
Language: English
Description
Summary:Although there is considerable published literature on micro-metal forming processes, there is still a lack of research towards implementing these processes commercially. Some of the challenges are handling of micro-parts and process intermittency. This work demonstrates the feasibility of producing symmetric micro-parts using a progressive forming set-up. Such a progressive forming process alleviates the challenges in handling and removal of micro-parts. Micro-pins with diameters of 0.3, 0.5, and 0.8 mm were successfully manufactured without defects. Experimental observations together with process simulation results showed that this process has three main stages: (1) indentation at the very beginning, (2) upsetting, and (3) extrusion predominantly occurring at the very end stage of the stroke. The bulk of the pin forming occurs at the end stroke of the process (extrusion stage). The effects of punch/pin diameter ratio on the pin aspect ratio and the maximum forming load were also investigated. In addition, the finite element results also revealed that a hybrid friction model was required to be implemented for better fit with experimental results as compared to the shear and Coulomb friction models.