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

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Abstract

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.

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Authors and Affiliations

  1. School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore, 639798, Singapore

    Ehsan Ghassemali

  2. Singapore Institute of Manufacturing Technology (SIMTech), 71 Nanyang Dr, Singapore, 638075, Singapore

    Ehsan Ghassemali & S. C. V. Lim

  3. School of Engineering, Jönköping University, P.O. Box 1026, 551 11, Jönköping, Sweden

    Anders E. W. Jarfors

  4. School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore, 639798, Singapore

    Ming-Jen Tan

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  1. Ehsan Ghassemali
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  4. S. C. V. Lim
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Correspondence to Ehsan Ghassemali.

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Ghassemali, E., Tan, MJ., Jarfors, A.E.W. et al. Progressive microforming process: towards the mass production of micro-parts using sheet metal. Int J Adv Manuf Technol 66, 611–621 (2013). https://doi.org/10.1007/s00170-012-4352-4

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  • DOI: https://doi.org/10.1007/s00170-012-4352-4

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