Journal articles: 'Micro forming process'

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Lee, Hye Jin, Nak Kyu Lee, and Seo Gou Choi. "Development of Miniaturized Micro Metal Forming Manufacturing System." Materials Science Forum 544-545 (May 2007): 223–26. http://dx.doi.org/10.4028/www.scientific.net/msf.544-545.223.

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The existing forming press uses a hydraulic actuator and high powered mechanical actuator, therefore occupying a large space because of its size. This type of system is inefficient for manufacturing micro size and precision products. As forming components are small in size, forming equipment must also be small in size because the forming die and load must be small. The micro forming manufacturing system is an ultra precision forming equipment the size of several micros to millimeters and precision of sub-micro to micrometer. This micro forming manufacturing system has the advantage of minimization in manipulating distance and working space. As equipment and tools become smaller in size, minute inertia force and high natural frequency can be obtained. Therefore, high precision forming performance can be obtained. This allows the factory to quickly provide the customer with goods because the manufacturing system and process are reduced. To construct a micro manufacturing system, many technologies are necessary such as high stiffness frame, high precision actuating part, structural analysis, high precision tools and system control. In this paper Research development about a micro metal forming manufacturing system has been developed. To coincide with the purpose to be more practical, we set the development of the equipment including micro deep drawing, micro punching and micro restriking process to the goal. To achieve this goal, the miniaturized micro metal forming manufacturing system is designed and made with miniaturized size system. A micro deep drawing process and system dynamic characteristic experiments are researched using this miniaturized micro forming system. A micro deep drawing experiment is performed using micro thin foil materials (Al-1100, SUS-304). If this miniaturized micro forming technology is used, efficient material practical use in the micro forming field which uses the micro metal thin foil is possible.

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Zheng, Wei, Guang Chun Wang, Tao Wu, and Li Bin Song. "Study on Formability of Micro-Feature in the Coining Process." Materials Science Forum 704-705 (December 2011): 129–34. http://dx.doi.org/10.4028/www.scientific.net/msf.704-705.129.

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In micro-manufacture field, micro-forming is paid much attention due to its efficiency for mass production. However, owing to the particularity of deformation, mass researches for specialized micro-forming processes to direct the industrial production are of great urgency. As a similar process with the micro-forming, the forming property of micro-feature forming in coining process was investigated by the experimental research and numerical analysis. Firstly, utilizing the workpieces with different thicknesses and micro-feature sizes, the coining processes were numerically simulated to study the forming property of micro-feature. The height of micro-feature was selected as the evaluation criteria for the deformation behavior. Then, the pure copper specimens with different thicknesses were coined experimentally, using a die with a micro-hole by the universal testing machine to verify the simulation results. Finally, a modified scheme was successful to be proposed which could improve the manufacturability of the processes. The research results could provide technical references for manufacturing micro-parts and those with micro-features.

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Lee, Hye Jin, Nak Kyu Lee, Sang Mok Lee, Geun An Lee, and Seung Soo Kim. "Development of Micro Metal Forming Manufacturing System." Materials Science Forum 505-507 (January 2006): 19–24. http://dx.doi.org/10.4028/www.scientific.net/msf.505-507.19.

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The micro metal forming manufacturing system is essentially an ultra precision forming press that can manufacture various micro scale products from metal thin foil and bulk material. In this paper, the micro metal forming manufacturing system has been developed using a micro servo motor. A micro forming system has been developed in Japan with a micro press that is limited to the single forming process. However, a press with a multi forming process is needed and we set about performing research and development of assorted equipment, including investigation into micro deep drawing and the micro punching process. In order to achieve this goal, exploration into the micro forming process as related to the multi forming process must be preceded first. Material selection and analysis of the micro forming process are accomplished in this paper, and the basis research as to how to make the actual system is accomplished.

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Vollertsen, Frank. "Size Effects in Micro Forming." Key Engineering Materials 473 (March 2011): 3–12. http://dx.doi.org/10.4028/www.scientific.net/kem.473.3.

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Size effects are effects which might occur, if the dimensions of a forming process are scaled up or down. They might enable or disable the application of a process in the micro range. Based on the systematic order of size effects, which defines density, shape and structure effects, one example for each group is given. A density effect, which occurs in Tiffany structures, explains the changes in forming behavior of foils with respect to the forming limit diagram. The feasibility of a new heading process only in the micro range is due to a shape effect, driven by the surface energy. The changes in the tribology in deep drawing by a structure effect, known as closed an open lubricant pocket model, can be explained only if one takes the temperature dependence of the viscosity of the lubricant into account.

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Lim, Samuel C. V., Yingyot Aue-U-Lan, Danno Atsushi, Mei Qian Chew, and Chow Cher Wong. "Process and Material Property Effects in the Progressive Forming of Micro-Pins." Key Engineering Materials 447-448 (September 2010): 432–36. http://dx.doi.org/10.4028/www.scientific.net/kem.447-448.432.

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A progressive forming process for micro-components was developed to circumvent the issue of handling of small micro-parts while keeping in mind the need for high manufacturing through-put. The mechanical properties and microstructure of the material have been found to play a significant role in the forming of micro-components. In this work, the effect of mechanical property on the forming of copper micro-pins by the progressive forming process is highlighted. Empirical results show that the forming load decreases for forming micro-pin with 0.3mm diameter after annealing but the pin height obtainable decreases as well compared to that prior to the heat treatment.

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Müller, Benedikt, and Andreas Schubert. "Generation of micro channels in AlMg4.5Mn0.7 sheets using a vibration-assisted micro forming process." MATEC Web of Conferences 190 (2018): 10003. http://dx.doi.org/10.1051/matecconf/201819010003.

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Micro forming can be used for a highly efficient manufacturing of small parts like screws or caps. Because of the small dimensions of the structures, high stresses and forming forces occur, especially in the case of micro bulk forming. In addition, the influence of friction is significantly higher compared to macro forming processes. A typical example of small structures are micro channels. An approach for the reduction of the necessary forming force to obtain lower loads on the tool consists in a vibration-assisted micro forming process. As vibration source, a piezo power module is placed directly in the force axis of the forming press. For the investigations, micro channels with a depth of more than 300 μm and a width of 300 μm are formed into 1.5 mm thick AlMg4.5Mn0.7 aluminium alloy sheets. The focus of the research lies in the influence of the process parameters like frequency and oscillation amplitude onto the material flow and the achieved channel depths. To investigate a possible influence on the friction conditions due to the vibration assistance, different lubrication conditions are applied. First results show a channel depth increase of 12 % compared to samples formed without vibration assistance.

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Wang, C. J., B. Guo, D. B. Shan, Y. Z. Wang, J. Zhou, and F. Gong. "Investigation of forming process for micro‐socket connecters." Materials Research Innovations 15, sup1 (February 2011): s225—s229. http://dx.doi.org/10.1179/143307511x12858957673473.

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Song, Jung Han, Jeanho Park, Jong Sup Lee, Seo Gou Choi, Hye Jin Lee, and Jeong Ho Hwang. "Micro Pattern Forming of Spiral Grooves in a Fluid Dynamic Bearing Using Desktop Forming System." Advanced Materials Research 538-541 (June 2012): 1203–7. http://dx.doi.org/10.4028/www.scientific.net/amr.538-541.1203.

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This research explores the micro-forming process of spiral groove pattern on Fluid Dynamic Bearing(FDB), which is utilized in precision driving part of the hard disk drive(HDD), using micro desktop forming system. While EDM and ECM process has been widely used to engrave the precision pattern which generates dynamic pressure on FDBs, micro forming process is newly proposed in this study to increase the productivity and to reduce the product costs. At first, desktop forming system is designed for spiral groove pattern forming. FE simulations are followed in order to evaluate the feasibility of micro-forming. The simulation results show that forming loads of 1,500Kgf is required to fabricate micro patterns with the depth of 15 μm. Finally the formability test is carried out with various forming loads. Deformed shapes and forming loads obtained from the test are compared with those from the analysis. The results fully demonstrate that micro pattern forming techniques are available to fabricate micro spiral groove patterns in FDB.

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Gau, Jenn-Terng, Hao Gu, Xinhui Liu, Kun-Min Huang, and Bor-Tsuen Lin. "Forming micro channels on aluminum foils by using flexible die forming process." Journal of Manufacturing Processes 19 (August 2015): 102–11. http://dx.doi.org/10.1016/j.jmapro.2015.04.006.

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Kinouchi, Yuki, Masahiko Yoshino, Hiroyuki Miyasaka, Nayuta Minami, Tomoyuki Takahashi, and Noritsugu Umehara. "Nano Forming Process for Functional Surface(M^4 processes and micro-manufacturing for science)." Proceedings of International Conference on Leading Edge Manufacturing in 21st century : LEM21 2005.2 (2005): 849–54. http://dx.doi.org/10.1299/jsmelem.2005.2.849.

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11

Yuan, H., Y. L. Li, G. L. Zhao, F. F. Liu, and F. Y. Li. "Incremental rolling forming process to fabricate surface micro-grooves." IOP Conference Series: Materials Science and Engineering 1270, no. 1 (December 1, 2022): 012033. http://dx.doi.org/10.1088/1757-899x/1270/1/012033.

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The fabrication of functional micro-structures at sheet surface has a wide range of applications in noise reduction, friction reduction, heat and mass transfer, etc. By integrating the conventional rolling forming and the incremental sheet forming process, a flexible and widely applicable incremental rolling forming process was proposed in the present work to fabricate surface micro-grooves. First, a rolling tool which has hemispherical ring convex on the roller and the convex height is much higher than the height of forming groove was designed and manufactured. Then, a series of incremental rolling tests on titanium alloy (TA1) were carried out by using self-designed rolling tools, with varying roller size, rolling depth and feed rate. The results show that continuous micro-grooves with good dimensional consistency were prepared on the surface of the plate. Furthermore, by investigating rolling force and groove size after rolling, it was found that the rolling depth have significant effects on the micro-groove formation and only localized material flow is occurred at the grooved region. Compared with the traditional rolling process, the incremental rolling process has the advantages of low rolling force and adjustable groove spacing, which is conducive to the subsequent processing of the sheet.

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Xu, Linhong, Yulan Lei, Haiou Zhang, Zhaochen Zhang, Yuchu Sheng, and Guangchao Han. "Research on the Micro-Extrusion Process of Copper T2 with Different Ultrasonic Vibration Modes." Metals 9, no. 11 (November 10, 2019): 1209. http://dx.doi.org/10.3390/met9111209.

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As an effective method for the fabrication of miniature metallic parts, the development of micro-forming process (MFP) is still restricted by the existence of size effect. To improve the micro-forming performance of metal material, ultrasonic vibration assisted MFP had been studied extensively for its superiorities in improving materials flow stress and reducing interfacial friction. However, from the literature available, the high frequency vibration was usually found to be superimposed on the forming tool while seldom on the workpiece. Our group developed a special porous sonotrode platform which can realize tool vibration and workpiece ultrasonic vibration independently. In this work, ultrasonic micro-extrusion experiments for copper T2 material under tool vibration and the workpiece vibration condition, respectively, were conducted for comparing the micro-forming characteristic of different vibration modes. The micro-extrusion experiment results of copper T2 show that the lower extrusion flow stress, the higher micro-extrusion formability and surface micro-hardness, and more obvious grain refinement phenomenon can be obtained under the workpiece vibration condition compared with that of tool vibration. These findings may enhance our understanding on different ultrasonic forming mechanisms and energy transmission efficiency under two different vibration modes.

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Zhao, Yue, Liang Luo, Zheng Yi Jiang, Xiao Ming Zhao, and Di Wu. "Study on Simulation and Experiment of Micro Sheet Metal Forming." Advanced Materials Research 941-944 (June 2014): 1876–81. http://dx.doi.org/10.4028/www.scientific.net/amr.941-944.1876.

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In the last few decades, there is a global interest in micro products, and micro forming of metals is a promising micro manufacturing method. However, a comprehensive understanding of this process is absent. Therefore, this study aims to investigate micro deep drawing process via experimental and analysis work. Simulation results are in good agreement with the experimental data. The comparison between the finite element method (FEM) simulation and experimental results shows the feasibility of FEM simulation for micro deep drawing process. This research also lays a fundament of investigating micro forming process, especially micro deep drawing.

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Luo, Liang, Haibo Xie, Dongbin Wei, Xiaogang Wang, Cunlong Zhou, and Zhengyi Jiang. "A new micro scale FE model of crystalline materials in micro forming process." MATEC Web of Conferences 80 (2016): 02002. http://dx.doi.org/10.1051/matecconf/20168002002.

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Meng, B., M. W. Fu, C. M. Fu, and J. L. Wang. "Multivariable analysis of micro shearing process customized for progressive forming of micro-parts." International Journal of Mechanical Sciences 93 (April 2015): 191–203. http://dx.doi.org/10.1016/j.ijmecsci.2015.01.017.

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Hopmann, Christian, and Jonathan Martens. "Influence of the Variothermal Process Control on Thermoforming of Micro-Structures." Key Engineering Materials 651-653 (July 2015): 855–62. http://dx.doi.org/10.4028/www.scientific.net/kem.651-653.855.

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Functional surface effects on plastic components are a matter of current research activities. To make these surface effects usable on an industrial scale, new processes have to be developed. Forming processes such as injection moulding are currently used to produce functional surfaces, but machine and tool costs are considerably high. Therefore, it is of high importance to analyse to what extent the thermoforming process can be applied to manufacture micro-structures.The so called In-Mould-Graining (IMG) process is a promising variant of the thermoforming enabling the manufacture of micro-structures. The advantage of the IMG process is, that the structure is formed to the final shape of the part. If the structure on the film surface is set before the forming, the conversion may cause a deformation of the structure. However, the forming accuracy of the IMG process is limited by the rapid cooling of the film at the cold mould surface. A significant time interval between the heating and the forming leads to a cooling of the film, especially at its surface and thereby reduces the forming accuracy in the area of the grains.In this paper it is investigated to what extent the moulding accuracy of the IMG can be increased by the use of a variothermal mould heating. To achieve the required forming accuracy, only the surface layer of the micro-structured region of the cavity is heated by induction before the contact between film and cavity occurs. At the same time, the entire mould is cooled with a conventional water cooling system. The analysis of the process and formed parts shows, that especially the mould temperature during the forming process has a significant impact on the forming accuracy. A forming accuracy of a 50 µm high micro-structure of more than 95 % can be achieved. Furthermore, the contact of angle of a water droplet on a micro structured thermoformed surface can be increased up to + 145°.

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Cho, Won Seung, Myeong Woo Cho, and Dong Sam Park. "Micro Groove Forming on AlN/hBN Composites Using Powder Blasting Process." Materials Science Forum 510-511 (March 2006): 1018–21. http://dx.doi.org/10.4028/www.scientific.net/msf.510-511.1018.

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In this study, powder blasting techniques are applied for micro groove forming on the developed AlN/hBN composites. First, material properties of the composites are evaluated according to the variation of h-BN contents. And, a series of required experimental works are performed to determine optimum powder blasting conditions for micro groove forming. The experiments are performed for the prepared samples with masked patterns. As the results, it can be observed that the machiniability of the developed AlN/hBN composites increases as h-BN contents in the composites. Also, from the experimental results, it is possible to determine the optimum blasting conditions for micro groove forming on the developed AlN/hBN composites.

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Brüning, Heiko, Mischa Jahn, and Alfred Schmidt. "Process Window for Forming of Micro Preforms at Different Temperatures." Advanced Materials Research 769 (September 2013): 173–80. http://dx.doi.org/10.4028/www.scientific.net/amr.769.173.

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Parts, which dimensions do not exceed the micro range are gaining more importance in today´s goods due to miniaturization and function compaction of products. Thus, fabrication methods for these special, very small parts attract notice because whole processes or at least process parameters cannot be transferred into micro range. Nevertheless, this does not necessarily mean, that size-effects are always detrimental as there are some processes which can only be carried out in micro range such as the laser-based micro upsetting process. The basic characteristics of this process are presented in this paper such as its self-aligning capability. Due to the fact that the maximum achievable upset ratio in single stage upsetting decreases with decreasing sample size, the material accumulation represents a very good semi-finished product (preform) being formed in a succeeding upsetting process. A temperature- and time controlled forming unit has been developed which is directly adapted to the laser system which is required to generate the preform. Thus, either a pre-defined temperature of the preform or the down time gives the initial signal to start the forming process. In this paper, a mathematical model is very briefly presented to determine the process window for forming preforms at certain well defined temperatures regarding size-effects.

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Chang, Chao Cheng, Shuo Kai Pan, and Kuan Te Yu. "Forming Limit in the Nosing Process of Micro Copper Cups." Key Engineering Materials 794 (February 2019): 121–26. http://dx.doi.org/10.4028/www.scientific.net/kem.794.121.

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This study used finite element simulations and experiments to investigate the forming limit in the nosing process of micro copper cups, and to establish the limit nosing curves in terms of nosing ratio, die angle, and friction factor. Two-stage processes, including backward extrusion and nosing processes, were considered in simulations and experiments at micro scale. The copper billets with 1 mm diameter and length were backwards extruded to produce the 1 mm diameter cups with 0.1 mm wall thickness. The cups were later used in the nosing processes under different forming conditions. By analysing the results of the nosed cups from the simulations, it is possible to identify the safe and failure forming conditions and establish the limit nosing curves for the nosing process. The simulation results show that the limit nosing ratio increases as the die angle or friction factor decreases. Two predicted results for poor and well lubricated conditions have been examined and are in good agreement with those from experiments. The study not only explores the characteristics of the noise process of copper cups at micro scale but also establishes the limit nosing curves which could be the guidelines for the design of micro metal components.

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Hirao, Atsutoshi, Takayuki Tani, and Naotake Mohri. "D22 Micro-pin Forming Method by Scanning EDM : Multi Step Process for Micro-pin Forming with High Aspect Ratio." Proceedings of The Manufacturing & Machine Tool Conference 2014.10 (2014): 237–38. http://dx.doi.org/10.1299/jsmemmt.2014.10.237.

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Deng, Zhong Lin. "The Study of Microscale Effect Assessment in Micro Forming." Advanced Materials Research 971-973 (June 2014): 216–19. http://dx.doi.org/10.4028/www.scientific.net/amr.971-973.216.

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Metal micro forming is microscale effect in the process of classification and evaluation, for the correct understanding of micro forming and conventional forming difference, it is guiding significance in the course of micro forming technology similar to conventional forming which is applied to the data and experience. The microscale effect is beneficial to accurate grasp of all kinds of microscale effect in the forming reasonable classification and evaluation.Change law of microscale affects the nature of knowledge for the right team which provides effective quantitative data, when determine the major hours of rights, it also can provide the guiding idea for material selection and process optimization.The reasonable classification and evaluation of microscale effect is the experience that conventional forming calculation provides a reality way. In all kinds of process load calculation, as long as the material intrinsic microscale is joined, microscale can be introduced in corresponding few and the process conditions.

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Musa, Mohd Azam, Akhtar Razul Razali, and Nazrul Idzham Kasim. "Grain and Feature Size Effect on Material Behavior for Micro-Sheet-Forming." Applied Mechanics and Materials 680 (October 2014): 77–80. http://dx.doi.org/10.4028/www.scientific.net/amm.680.77.

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Negligible factors in bulk materials, such as grain-size effects, have proven inappropriate to be neglected for micro-forming processes. Studies had shown that material behavior varies greatly with the increasing of the scale in the micro-forming world. Therefore, in every micro-forming-related process, especially in micro-stamping, studies and analyses of each material used for the process have to be considered as indispensable in order to be able to understand their behavior and to be able to correlate their behavior with the process. Uniaxial tensile-testing experiments have been carried out to determine the strip’s properties, behavior and its correlation with the feeding process in micro-stamping/micro-sheet-forming application. Based on the results of the uniaxial tensile-test experiments conducted, the flow stress was found to decrease with the decrease of the strip thickness and vice versa, due to the size/scale effect. A surface model was used to explain the findings.

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Müller, Benedikt, and Andreas Schubert. "Micro structuring of AlMg4.5Mn0.7 sheets by a warm forming process." Procedia Engineering 207 (2017): 1045–50. http://dx.doi.org/10.1016/j.proeng.2017.10.1128.

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Tang, Y., Y. Chi, Z. P. Wan, X. K. Liu, J. Ch Chen, X. X. Deng, and L. Liu. "A novel finned micro-groove array structure and forming process." Journal of Materials Processing Technology 203, no. 1-3 (July 2008): 548–53. http://dx.doi.org/10.1016/j.jmatprotec.2007.11.070.

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Jin, Ying, Jian Hua Wu, Yong Jun Shi, Hong Shen, and Zheng Qiang Yao. "Research on the Mechanisms of Laser Forming for the Micro-Structural Element." Materials Science Forum 575-578 (April 2008): 1145–50. http://dx.doi.org/10.4028/www.scientific.net/msf.575-578.1145.

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Laser forming of a micro-structural element involves a complex thermoplastic process. Numerous efforts had been made on the mechanisms of laser forming for macro-size elements, such as temperature gradient mechanism, buckling mechanism and upsetting mechanism, etc. It is found that the three mechanisms cannot depict fully the process of deformation in the macro-size element forming, let alone meet the needs of the micro-size one. Considering the laser inducing thermal stresses with size factors differing from the conventional analysis, it is essential to reveal the mechanisms dominating the forming process to accurately control the bending angle of a tiny plate. By studying the thermal transfer and elastic-plastic deformation of micro-structural element laser forming, the forming mechanism is explained within the micro size. The finite element model for laser bending is constructed for simulation. The stimulation results are agreement with the experimental data.

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Sharma, Sachin Kumar, Basanth Kumar Kodli, and Kuldeep Kumar Saxena. "Micro Forming and its Applications: An Overview." Key Engineering Materials 924 (June 30, 2022): 73–91. http://dx.doi.org/10.4028/p-3u80qc.

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A Micro forming was primarily developed in order to view the usage and significance of micro metal forming technology. It is implemented for the manufacturing and production of micro metallic devices like micro pump, micro gears (Polyoxymethylene polymer), Biodegradable implants (Polylactic acid) etc. The die assembly is provided with a DLC (Diamond like coating) coating during work study to resolved small size dimensional accuracy issue and enhanced tribological properties. Various High Energy Metal Forming processes (HERF) is discussed like ultrasonic vibration, explosive forming, magnetic forming, electro hydraulic forming, ultrasonic vibration and heating process for enhancement in formability and accuracy to the product of micro scale dimension. The detailed review of Micro forming and its applications in various fields that utilized the various high energy processes is discussed in this paper. Keywords: Biodegradable, Tribological Properties, HERF (High Energy Rate forming), Formability.

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Peng, Zi Long, Zhen Long Wang, and Bai Dong Jin. "Micro-Forming Process and Microstructure of Deposit by Using Micro EDM Deposition in Air." Key Engineering Materials 375-376 (March 2008): 153–57. http://dx.doi.org/10.4028/www.scientific.net/kem.375-376.153.

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Based on analysis of the mechanism of Electrical Discharge Machining (EDM) and the characteristics of deposition processing, the processing conditions of micro EDM Deposition (micro EDD) are determined. Micro EDD is a new EDM method taking air as machining medium, using narrow pulse width, long pulse interval, low discharge current and connecting the tool electrode with the anode of pulse generator. Using EDM shaping machine and brass, tungsten and steel as tool electrode respectively, micro cylinders are deposited on high-speed steel surface. And then the microstructure of deposit is analyzed detailedly. Results show that elements of the deposited material distribute uniformly, whose components depend on the tool electrode material. As the high cooling rate of the solidification process, the deposit grain size refines obviously, which leads to the hardness of tungsten or steel deposit increasing. Moreover, the Metallurgical bonding has occurred on the interface between deposit and high-speed steel base, whose thickness is about 5μm.

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Nanthakumar, S., D. Rajenthirakumar, and S. Avinashkumar. "Influence of temperature on deformation behavior of copper during microextrusion process." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 234, no. 9 (January 8, 2020): 1797–808. http://dx.doi.org/10.1177/0954406219899114.

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Micro scale deformational behavior of metals is improved upon increasing the room temperature. Further, the drawbacks of micro forming caused by size effects are reduced significantly. In the current work, investigation on the material behavior of copper at elevated temperature ranging from room temperature to 200 ℃ is conducted. On the experimental part, a novel micro extrusion die set assembly has been developed along with temperature assistance, where the specimen is heated within the die assembly to study deformation behavior. When the forming temperature is raised, an enlargement of the forming limits is achieved along with a significant reduction in extrusion force. Further, the flow of material inside the die orifice was more uniform, and the micro pin showed a good replication of the die dimensions with homogeneous material deformation. During the increase of extrusion temperature and lubrication conditions (diamond-like carbon coating), the micro pin is more complete with higher dimensional accuracy and surface finish. The investigation on the influence of temperature showed that there is a reduction in microhardness of samples compared to the hardness of samples extruded at room temperature. However, there is a significant reduction of scattering due to homogenizing effect.

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Huang, Kun Lan, Yi Yang, and Yi Qin. "Sintering Kinetics of the Powder during Fields-Activated Micro-Forming and Sintering (Micro-FAST) of Copper Micro-Gears." Key Engineering Materials 622-623 (September 2014): 854–60. http://dx.doi.org/10.4028/www.scientific.net/kem.622-623.854.

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Forming of micro-components from powder with fields-activated sintering technology (FAST) renders different forming and sintering mechanisms, comparing to that occurring during the forming of macro-sized components with a similar technology. Establishing a good understanding of these mechanisms would help process design and control aiming at achieving desired quality of the components to be formed. This paper presents a study and the results on the sintering kinetics of the powder during Micro-FAST for the fabrication of micro-gears (the module is 0.2 and the pitch diameter 1.6 mm) from copper powder. The results showed that the densification of copper powder is related largely to the bulk plastic-deformations of the particles and the melting of the particles at contact interfaces. Particularly, it is revealed that plastic deformations of the copper particles mainly occurred at approximately 340 °C and melting of the particle-interfaces at approximately 640 °C. Differently, in a densification process with a traditional powder sintering method, grain growth and neck growth would, normally, be two dominant mechanisms that achieve the densification of powder.

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Li, Xibing, Zhixiong Ye, Nanpeng Li, Jialun Chen, and Tengyue Zou. "Ploughing-Pulling Forming for Wicking Structure of Flat Micro-Groove Heat Pipe and Machine Tool Optimization." Journal of Mechanics 36, no. 4 (February 27, 2020): 423–35. http://dx.doi.org/10.1017/jmech.2019.53.

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ABSTRACTIn forming procedure of the micro grooves in the flat micro-groove heat pipe, the tie rod is often observed to be broken and the multi-tooth cutter is damaged due to the sharp increase of the ploughing-pulling pressure. This paper theoretically analyzes the factors affecting the capillary heat transferring limit of the micro-groove heat pipe, and simulates the machining process using finite element to acquire the best processing parameters: the squeeze angle is 120°, the drawing depth is 0.25mm, and the ploughing-pulling velocity is 100mm/s. Then these parameters are verified by real manufacturing experiments. The experimental results show that the ploughing-pulling pressure of the micro-groove forming process is close to the strength limit of the rod or multi-tooth cutter, and the process makes little swarf during work. Thus, only using the appropriate machine tool parameters, forming parameters and forming methods can make the wicking structure of flat micro-groove micro-heat pipe with the best heat transferring performance.

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Xu, Jie, Bin Guo, Debin Shan, Chunju Wang, Juan Li, Yanwu Liu, and Dongsheng Qu. "Development of a micro-forming system for micro-punching process of micro-hole arrays in brass foil." Journal of Materials Processing Technology 212, no. 11 (November 2012): 2238–46. http://dx.doi.org/10.1016/j.jmatprotec.2012.06.020.

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Yoo, Ju Hyun, and Wei Gao. "Near-Net Ceramic Micro-Tubes Fabricated by Electrophoretic Deposition Process." International Journal of Modern Physics B 17, no. 08n09 (April 10, 2003): 1147–51. http://dx.doi.org/10.1142/s021797920301865x.

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The forming or shaping of ceramic micro-tubes is usually difficult with conventional ceramic processing. In some cases, parts that are not possible to produce by any other techniques can be fabricated with electrophoretic deposition process (EPD). In this paper, EPD is shown to be an operationally simple, rapid, and reliable technique for forming a wide range of ceramic micro-tubes required in electronic devices such as actuators, motors, optical modulators and MEMS. These topics will be discussed in detail.

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HAN, JEONGWON, BYUNG-KWON MIN, and SHINILL KANG. "MICRO FORMING OF GLASS MICROLENS ARRAY USING AN IMPRINTED AND SINTERED TUNGSTEN CARBIDE MICRO MOLD." International Journal of Modern Physics B 22, no. 31n32 (December 30, 2008): 6051–56. http://dx.doi.org/10.1142/s021797920805156x.

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Glass microlens array with lens diameter under 100 µm was replicated by micro thermal forming process using a tungsten carbide micro mold which was imprinted and sintered from an original master. The original master was fabricated by photolithography and thermal reflow process. The effects of forming process conditions on the form accuracy and the surface roughness of the micro formed glass microlens array were examined and analyzed. Finally, to verify the effectiveness of the proposed process, glass microlens array for the purpose of laser beam focusing was designed and fabricated, and a focused laser beam profile using the fabricated microlens array was measured and analyzed.

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Na, Young Sang, S. G. Kang, K. Y. Park, and Jong Hoon Lee. "Estimation of Micro-Formability and FEM Simulation of Micro-Forming Process of a Zr-Based Bulk Metallic Glass." Materials Science Forum 539-543 (March 2007): 2129–34. http://dx.doi.org/10.4028/www.scientific.net/msf.539-543.2129.

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Micro-forming is considered to be a suited technology to manufacture very small metallic parts (several μm~mm). Zr-based bulk metallic glass, Zr62Cu17Ni13Al8, has been expected to be a promising metallic material for micro-forming process due to their isotropy, low flow stress in a wide supercooled liquid region and good stability of amorphous matrix. Therefore, one can expect that micro-forming of Zr62Cu17Ni13Al8 might be feasible at a relatively low stress in the supercooled liquid state without any crystallization during hot deformation. In this study, micro-formability of Zr62Cu17Ni13Al8 bulk metallic glass was investigated for micro-forging of U-shape pattern. Microformability was estimated by comparing Rf values (=Af/Ag), where Ag is corss-sectional area of U groove, and Af the filled area by material. Micro-forging process was also simulated and analyzed by applying the finite element method. The micro-formability of Zr62Cu17Ni13Al8 was increased with increasing load and time in the temperature range of the supercooled liquid state. In spite of the similar trend in the variations of Rf values, FEM simulation results showed much higher Rf values than the experimental Rf values. This disagreement was analyzed based on the stress overshoot phenomena of bulk metallic glasses in the supercooled liquid region. FEM simulation of the microstamping process was applicable for the optimization of micro-forming process by carefully interpreting the simulation results.

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Chu, Xu Yang, Po Li, Wen Dong Xue, Chao Meng, and Guan Xin Chi. "Study of Combined Process in Micro-EDM." Advanced Materials Research 418-420 (December 2011): 1405–9. http://dx.doi.org/10.4028/www.scientific.net/amr.418-420.1405.

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Micro-EDM is a flexible process which has many technique methods such as forming, drilling, milling, copying and WEDM. Combined these methods together can enhance the EDM machining ability. In this paper a set of route design regulations used in combined machining is proposed. Through these regulations, the optimal route of combined process can be obtained which can improve high machining quality and efficiency. To test performance of the regulations, the combined route of a micro part is designed and its fabrication is performed at last.

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Hu, Peng, Lin Fa Peng, Xin Min Lai, and Wei Gang Zhang. "Micro/Meso Scale Metallic Sheet Forming Process Analysis Based on the Strain Gradient Plasticity Theory." Materials Science Forum 675-677 (February 2011): 991–94. http://dx.doi.org/10.4028/www.scientific.net/msf.675-677.991.

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Increasing demands for miniature metallic parts have driven the application of micro/meso forming process in various industries. The present study focuses on the size effect which appears in the micro/meso scale sheet forming process. Micro/meso scale stamping experiments and finite element simulations incorporating the CMSG plasticity theory are conducted, respectively. It is found that the numerical simulation results, with strain gradient and strain gradient path taken into account, match the experimental results better than those of conventional simulation method.

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Hu, Fu Qiang, Jian Fei Sun, Jun Qi Wei, Yong Zhang, Yan Dong Jia, Yue Rui Zhao, and Ting Yi Liu. "Research on the Process of High Silicon Aluminum Alloy in MEDM." Advanced Materials Research 634-638 (January 2013): 1766–70. http://dx.doi.org/10.4028/www.scientific.net/amr.634-638.1766.

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Because of the high content of Si, traditional machining can hardly machine micro and small structures. While there is almost no microscopic force in the process of micro-electrical discharge milling (MEDM), so it has great advantages. In the process of MEDM for high silicon aluminum (Si-Al) alloy, the impacts of electrical parameters on processing time, the trend and degree of electrode wear are researched. The Al-50wt%Si alloy made by spray forming (SF) and casting forming (CF) and electrode of copper and tungsten are adopted to do the research. Related processing laws are summarized. A micro-3D structure was made by using appropriate parameters based on the experiment and research.

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Schulze Niehoff, H., Zhen Yu Hu, and Frank Vollertsen. "Mechanical and Laser Micro Deep Drawing." Key Engineering Materials 344 (July 2007): 799–806. http://dx.doi.org/10.4028/www.scientific.net/kem.344.799.

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Mechanical micro deep drawing becomes a more and more industrial relevant process. But due to size effects new challenges are involved in this process compared to macro deep drawing. The size effects cause an increase of friction and thus hinder the material flow. The change of friction in mechanical micro deep drawing is subject of the presented investigations in this paper. Additionally to this, a new non-mechanical micro deep drawing process is presented, whereby a laser beam acts as a punch. This new laser deep drawing process is based on a totally different mechanism compared to thermal laser forming, e.g. forming by laser induced thermal stresses: The laser produces a pulse with an extremely high power density, which causes plasma generation at the target and thus a shock wave. The shock wave can be used as in explosive forming, but is smaller and easier to generate. Recent investigations showed that using this technology laser deep drawing is possible with a sheet metal out of Al 99.5 and a thickness of 50 'm. The deep drawing process was carried out with a die diameter of 4 mm and shows promising results.

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Mahmood, Zaid H., Ihsan K. Irthiea, and Kadum A. Abed. "Experimental and Simulation investigations of Micro Flexible Deep Drawing Using Floating Ring Technique." Al-Khwarizmi Engineering Journal 14, no. 3 (August 15, 2018): 20–31. http://dx.doi.org/10.22153/https://doi.org/10.22153/kej.2018.12.007.

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Micro metal forming has an application potential in different industrial fields. Flexible tool-assisted sheet metal forming at micro scale is among the forming techniques that have increasingly attracted wide attention of researchers. This forming process is a suitable technique for producing micro components because of its inexpensive process, high quality products and relatively high production rate. This study presents a novel micro deep drawing technique through using floating ring as an assistant die with flexible pad as a main die. The floating ring designed with specified geometry is located between the process workpiece and the rubber pad. The function of the floating ring in this work is to produce SS304 micro cups with profile radius precision as required as possible. The finite element simulations are accomplished using the commercial code Abaqus/Standard. In order to verify the simulation models, micro deep drawing experiments are carried out using a special set up developed specifically to meet the requirements of the simulations. The results revealed that the proposed technique is feasible to be adopted for producing micro cups with remarkable application capability in miniaturization technology.

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Mahmood, Zaid H., Ihsan K. Irthiea, and Kadum A. Abed. "Experimental and Simulation investigations of Micro Flexible Deep Drawing Using Floating Ring Technique." Al-Khwarizmi Engineering Journal 14, no. 3 (August 15, 2018): 20–31. http://dx.doi.org/10.22153/kej.2018.12.007.

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Micro metal forming has an application potential in different industrial fields. Flexible tool-assisted sheet metal forming at micro scale is among the forming techniques that have increasingly attracted wide attention of researchers. This forming process is a suitable technique for producing micro components because of its inexpensive process, high quality products and relatively high production rate. This study presents a novel micro deep drawing technique through using floating ring as an assistant die with flexible pad as a main die. The floating ring designed with specified geometry is located between the process workpiece and the rubber pad. The function of the floating ring in this work is to produce SS304 micro cups with profile radius precision as required as possible. The finite element simulations are accomplished using the commercial code Abaqus/Standard. In order to verify the simulation models, micro deep drawing experiments are carried out using a special set up developed specifically to meet the requirements of the simulations. The results revealed that the proposed technique is feasible to be adopted for producing micro cups with remarkable application capability in miniaturization technology.

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Asghari Ganji, Amirreza, Mohammad Bakhshi-Jooybari, and Hamid Gorji. "Forming of micro gears by compressing a pure copper sheet through its thickness." MATEC Web of Conferences 190 (2018): 10004. http://dx.doi.org/10.1051/matecconf/201819010004.

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Currently, micro gears are mostly fabricated by LIGA technology and micromachining. These processes have some limitations. Forming processes not only satisfy mass production and appropriate productivity rate but also present superior mechanical properties. A major problem preventing the bulk micro metal forming is the preparation of micro billets and their precise transfer between the forming stages. The purpose of this study is developing a method to form a micro gear without the need to a separate micro billet preparation. In this paper, pure copper sheets were compressed into the predetermined micro gear profiles though their thicknesses, so that there is no need for preparation of micro billets and also its troublesome transforming. The tests were performed at room temperature, in two cases of single extrusion process and extrusion-forging process. Micro gears with 6 teeth and 250μm in module were formed completely with good repeatability in both the cases. A major advantage of the proposed study compared with the blanking process is that, in blanking, the process is merely cutting the edges, while here the material fills the die by deformation. Thus, better mechanical properties will be achieved. Measuring the micro-hardness of the formed parts in comparison with raw material, verified this point. In general, the micro-hardnesses of combined extrusion-forging parts were higher than those of single extrusion ones in the same positions on the micro gears surface.

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Behrens, Gerrit, and Frank Vollertsen. "Influence of Tool Geometry Variation on the Punch Force in Micro Deep Drawing." Key Engineering Materials 554-557 (June 2013): 1306–11. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.1306.

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Micro forming processes are very well suited for manufacturing of small metal parts in large quantities and micro deep drawing provides a great application potential for the manufacturing of parts with complex shapes. But size effects like changed tribology and material properties usually result in smaller process windows for micro forming operations. Process caused wear as well as large inaccuracy in manufacturing of micro forming tools is responsible for geometrical deviation of the tools from nominal size. Both influences can have essential impact on the process window size and process stability. A better understanding of the influence of tool geometry on process stability can help to improve and optimize process control in micro forming. In addition, a quantitative judgment of the impact of wear and manufacturing inaccuracy will be possible. Therefore, in this study, the impact of different tool geometries on the punch force in micro deep drawing was investigated. Significantly varied tool geometries were punch diameter, drawing gap, punch and drawing die radius and shape of the die edge. FEM simulations as well as experiments were used to determine tool geometry influence on the punch force of a micro deep drawing process. Hereby, it was possible to classify each geometry variation regarding its impact on the punch force and therefore on one important parameter of the process stability. Results show that the greatest impact on the punch force was caused by modifications of the punch diameter and variation of the drawing gap. Changes in punch or drawing die radii proved to be of minor importance.

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Sekine, Tsutomo, and Toshiyuki Obikawa. "Micro Incremental Forming Characteristics of Stainless Foil." Key Engineering Materials 447-448 (September 2010): 346–50. http://dx.doi.org/10.4028/www.scientific.net/kem.447-448.346.

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Single point micro incremental forming (SPMIF) was applied to the forming of a meso-scale pyramid. A type 304 stainless foil with a thickness of 8 μm and a household aluminum foil with a thickness of 12 μm were used as blanks. It was found that the elongation of stainless foil was relatively large in SPMIF although it is negligibly small in tensile test. Consequently, stainless foil exhibited larger ratio of elongation in SPMIF to that in tensile test than the ratio of aluminum foil. The enhancement of formability of stainless foil in SPMIF was discussed from a viewpoint of martensitic transformation. The surface condition associated with the process of SPMIF was inspected through AFM diagnosis.

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Yoshida, Yoshinori, Takashi Ishikawa, and Tomoaki Suganuma. "Mechanism of Forming Joining on Backward Extrusion Forged Bonding Process." Advanced Materials Research 966-967 (June 2014): 461–70. http://dx.doi.org/10.4028/www.scientific.net/amr.966-967.461.

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A backward extrusion forged bonding using low carbon steel and pure aluminum is conducted. The bonding strength between the materials is evaluated by a micro tensile test that is cut out at the bonding boundary. The maximum bonding strength is larger than that of the aluminum. In addition, the metallurgical mechanism of the joining of the backward extrusion forged bonding is investigated by means of a scanning transmission electron microscope (STEM). An intermetallic compound (IMC) layer is produced at the boundary with a thickness of about 3 nm. The process is applied for bonding between aluminum-nickel and between aluminum-copper. The bonding strength between the materials was evaluated by using a micro tensile test and the maximum bonding strength is shown. Fractured surfaces of the tensile specimens are observed by scanning electron microscope (SEM) and relationship between bonding strength and position on the boundary is discussed.

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Moeinifar, Sadegh. "Influence of Anisotropy Behavior in UOE Process for X80 Micro Alloy Steel." Advanced Materials Research 287-290 (July 2011): 2161–64. http://dx.doi.org/10.4028/www.scientific.net/amr.287-290.2161.

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The anisotropy of tensile properties and charpy impact fracture toughness and its relationship with UOE pipe forming has been study on X80 micro alloy steel. All samples selected from 90º and 180º of pipes in transverse and longitudinal orientations after UOE forming. The steel was supplied as a hot rolled plate with accelerated cooling. Microstructure of the micro alloy steel was various combinations of acicular ferrite, granular ferrite and M/A phases. Charpy impact fracture toughness tests were carried out in -50 °C to 0 °C. Minimum and maximum yield strength appears in the 180º and 90º of pipe in longitudinal and transverse orientations respectively. Increasing in the yield strength related to minimum amount was about 5.8 % after UOE forming. Comparison between yield strength after and before forming appears increased about 6.9 % due to forming. With decreasing in the test temperature from -50 °C to 0 °C, fracture energy decrease up to 0.9 % that it’s very little and relinquishment. However for samples that fractured in the temperature of -50 °C difference between highest and lowest energy was about 5.9 %. Charpy test results appear that fine M/A phase not a major factor on decrease of upper shelf energy, if homogenize distributed in the acicular ferrite matrix.

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Czotscher, Tobias. "Forming Behaviour of Micro-Structured Aluminium Sheets." Advanced Materials Research 1140 (August 2016): 11–18. http://dx.doi.org/10.4028/www.scientific.net/amr.1140.11.

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For a deeper understanding of the forming behaviour of perforated aluminium sheets (Al99.5) in micro deep drawing processes, tensile and stretch forming tests are performed at forming speeds of 0.1 mm/s and 0.25 mm/s. The sheets have thicknesses of 100 µm and 200 µm, a perforated rectangular hole geometry of 300 µm x 300 µm and a bar width of 40 µm. During stretch-forming tests the flow characteristics and failure mechanisms within the mesh structure are determined. An isotropic forming behaviour with low ductility is observed. The maximum stretch-forming depth is increased at increasing perforated area. The mesh structure failure is peripherally obtained due to notch effects, friction and micro related size effects within the mesh structure. Moreover, the results show that cracks and necking within the mesh structure occur only tangentially to the punch movement due to high uniaxial stresses caused by the forming process.

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Chang, Chao-Cheng, and Sin-Siang Huang. "Study on micro nosing process assisted by ultrasonic vibration." MATEC Web of Conferences 185 (2018): 00005. http://dx.doi.org/10.1051/matecconf/201818500005.

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This study used experiments to investigate the effect of ultrasonic vibration on the micro nosing process of copper cup. The billets with 1 mm diameter and length were backwards extruded to form the cups with 0.1 mm wall thickness and 1.8 mm height. The cups were then used in micro nosing processes. A forming system with the ultrasonic vibration has been developed and installed on a precision press to conduct the experiments. An optical fibre sensor and a precession load cell were equipped on the ram of the press in order to accurately measure the load and stroke of the process. Two forming conditions with and without ultrasonic vibrations of 20 kHz were considered in this study. The results show that the ultrasonic vibration can improve the materials flow which leads to an even diameter along the shrunk region of the nosed cup. Moreover, the ultrasonic vibration greatly reduces the load in the micro nosing process of the copper cup.

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Brinksmeier, Ekkard, Oltmann Riemer, Christian Robert, and Sven Twardy. "Advanced Machining Processes for Micro Mold Fabrication." Key Engineering Materials 523-524 (November 2012): 1018–23. http://dx.doi.org/10.4028/www.scientific.net/kem.523-524.1018.

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This paper presents two alternative approaches in mold making for micro forming processes. The quality of formed micro parts is mainly dominated by the process parameters and the surface characteristics of the applied forming tools. Forming dies with advanced micro structures can improve the result of forming processes compared to tools with smooth surfaces. Here an approach of micro ball end milling is described to generate the macro geometry as well as an engineered surface texture on micro forming tools in one machining step. In addition to the surface topography, the die material has a decisive influence on the forming result and durability of the forming tool. Therefore single crystalline diamond represents an promissing material for forming tools, because of its unique material characteristics. On the other hand single crystalline diamond requires unreasonable high efforts for its geometrical shaping. Therefore, this paper will introduce a new approach to machine single crystalline diamond by thermo-chemical material removal.

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CHI, Yong, Yong TANG, Jin-chang CHEN, Xue-xiong DENG, Lin LIU, Zhen-ping WAN, and Xiao-qing LIU. "Forming process of cross-connected finned micro-grooves in copper strips." Transactions of Nonferrous Metals Society of China 17, no. 2 (April 2007): 267–72. http://dx.doi.org/10.1016/s1003-6326(07)60083-1.

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Deng, J. H., M. W. Fu, and W. L. Chan. "Size effect on material surface deformation behavior in micro-forming process." Materials Science and Engineering: A 528, no. 13-14 (May 2011): 4799–806. http://dx.doi.org/10.1016/j.msea.2011.03.005.

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Journal articles on the topic 'Micro forming process'

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