Experimental and simulation studies of micro blanking and deep drawing compound process using copper sheet
Experimental and simulation studies of micro blanking and deep drawing compound process using copper sheet
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DOI：
10.1016/j.jmatprotec.2012.08.007
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发表时间：
2013-01-01
影响因子：
6.3
通讯作者：
Chan, W. L.
中科院分区：
文献类型：
--
作者：
Fu, M. W.;Yang, B.;Chan, W. L.
微成形技术具有生产效率高、生产成本低、产品质量好等优点，是一种很有发展前途的微制造技术。然而，尺寸效应的出现给工艺确定、模具设计和产品质量控制带来了不确定性，使设计充满挑战。因此，深入研究微成形过程中材料的变形行为对于开发优质微型零件至关重要。本研究针对铜板进行微复合冲裁与拉深成形。为了研究尺寸效应，将相似理论应用于模具设计和变形过程模拟。通过制备不同晶粒尺寸的铜板，研究了晶粒尺寸效应，并通过采用不同的冲头半径，研究了特征尺寸效应。通过对实验结果的分析发现，变形载荷随晶粒尺寸的增大而减小，但当板材横截面中晶粒数量较少时，这种减小并不显著。随着成形件尺寸的减小和晶粒尺寸的增大，变形变得不均匀。这进一步导致成形部件的不规则几何形状和粗糙表面光洁度。此外，还进行了模拟，以揭示整个拉深过程。模拟预测的变形载荷与试验结果趋势一致，但两者之间存在差异。这表明微成形过程的模拟需要考虑材料在成形过程中的不均匀变形。(C)2012爱思唯尔有限公司版权所有。
Microforming process is a promising micromanufacturing technology for producing microparts due to its high efficiency, low production cost and good product quality. The occurrence of size effect in the process, however, leads to the uncertainties in process determination, tooling design and product quality control and renders the design full of challenges. In-depth study of material deformation behavior in microforming process is thus crucial for development of quality microparts. In this research, the micro compound blanking and deep drawing of copper sheet is conducted. To investigate the size effect, the similarity theory is employed in die design and deformation process simulation. The grain size effect is studied by preparing the copper sheets with different grain sizes, while the feature size effect is also studied via using different punch radii. Based on the analysis of experimental results, it is found that the deformation load decreases with the increase of grain size, but this decrease is not significant when there are only a few grains in the cross section of the sheet metal. The deformation becomes inhomogeneous with the decrease of formed part size and the increase of grain size. This further leads to the irregular geometry and rough surface finish of the formed part. Furthermore, the simulation is carried out to reveal the entire deep drawing process. The deformation loads predicted by simulation have the same trend as the experimental ones, but the difference exists in-between. This indicates that the simulation of microforming process needs to consider the inhomogeneous deformation of material in the process. (C) 2012 Elsevier B.V. All rights reserved.