Validation of FE simulation based on surface roughness model in micro-deep drawing
Validation of FE simulation based on surface roughness model in micro-deep drawing
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DOI：
10.1016/j.jmatprotec.2007.10.081
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发表时间：
2008-08
影响因子：
6.3
通讯作者：
K. Manabe;Tetsuhide Shimizu;H. Koyama;M. Yang;K. Ito
中科院分区：
文献类型：
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作者：
K. Manabe;Tetsuhide Shimizu;H. Koyama;M. Yang;K. Ito
金属成形技术作为亚毫米级微小零件和大型零件最经济的批量生产方法之一，受到了广泛的关注。虽然工具和模具是制造微成形零件所必不可少的，但其制造的基础知识和技术数据尚未积累。因此，建立微成形工具、模具和坯料的设计手册和规范，对实现高精度成形具有重要意义。特别是在小型化的板料成形中，模具和坯料的表面粗糙度被认为在很大程度上影响着产品的加工特性和精度。从模具和坯料材料设计的角度出发，研究了微拉深过程中模具和坯料的表面粗糙度，旨在阐明表面粗糙度对微成形特性的影响。在前期的研究中，通过考虑表面粗糙度的有限元模拟，模拟了两步微拉深过程中工具表面粗糙度对拉深杯形件表面质量的影响。为了验证微拉深成形过程中表面粗糙度有限元模型的有效性，开发了一种新的高精度连续冲裁和拉深实验装置，并利用厚度为20μ m的不锈钢（SUS304）箔材制备了直径为500μm的微杯。为了评价拉制杯，测量杯的几何形状、厚度应变分布和表面粗糙度。通过有限元模拟与实验结果的对比，验证了表面粗糙度模型的有效性，并讨论了微观尺度下表面粗糙度的显著影响因素。
Metal forming technology has been paid great attention as one of the most economical mass production methods for sub-millimeter-scale microparts as well as macro-scale parts. Although tools and dies are essential for the manufacture of microformed parts, the fundamental knowledge and technological data on their fabrication have not been accumulated. Therefore, establishing design manuals and codes for tools, dies and blank materials for microforming is important for realizing high-precision forming. Particularly for miniaturization in sheet metal forming, the surface roughness of tools and blanks are thought to largely affect the processing characteristics and accuracy of products. From the standpoint of the design of tools and blank materials, this study was focused on the surface roughness of tools and blanks in the micro-deep-drawing process, and aimed at clarifying the effect of surface roughness on microforming characteristics. In our previous study, by finite element (FE) simulation considering surface roughness, the effect of tool surface asperity on the drawn cup surface quality in the two-stage micro-deep-drawing process was simulated. In this study, to verify the validity of the FE model of surface roughness in the micro-deep-drawing process, a new high-precision sequential blanking and drawing setup was developed for the experiment and a microcup with 500μm diameter was fabricated from stainless steel (SUS304) ultrathin foil of 20μm thickness. For the evaluation of the drawn cup, the cup geometry, thickness strain distribution, and surface roughness were measured. By comparisons of the FE simulation and the experimental results, the validation of the surface roughness model was studied, and the notable influential factors at the microscale were discussed.