Dieless incremental micro-forming of miniature shell objects of aluminum foils
Dieless incremental micro-forming of miniature shell objects of aluminum foils
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DOI：
10.1016/j.ijmachtools.2009.07.001
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发表时间：
2009-10-01
影响因子：
14
通讯作者：
Hakutani, Tomomi
中科院分区：
文献类型：
--
作者：
Obikawa, Toshiyuki;Satou, Shunsuke;Hakutani, Tomomi
针对薄壳类微小型件的定制化制造，提出了一种不需要模具和垫板的薄铝箔单点渐进成形方法。薄铝箔的变形增量使用一个圆形的尖端单点工具上的台式铣床与个人电脑控制。结果发现，当刀尖半径为0.5mm的单刃刀具不旋转时，12 μ m厚的铝箔的成形极限比50 μ m厚的铝箔的成形极限小得多，但当刀具旋转到20，000rpm时，其成形极限大大提高。测量的成形力显示，工具旋转减少了约50%的面内力。在旋转工具和铝箔之间的界面处的流体动力润滑必须对成形过程具有直接和有利的影响，同时增加较薄箔的成形极限。还发现，最佳的分步轴向进给被发现是周围的箔厚度的值。然后，在优化条件下，在12 μ m厚的箔的任意位置上，成功地进行了直径为0.1 mm的点阵列、微型金字塔、微型汽车和微型字母的增量成形。(C)2009爱思唯尔有限公司版权所有。
Single-point incremental forming of thin aluminum foils, which did not require any die and any backing plate, was developed for fabricating customized parts of thin shell miniature objects. Thin aluminum foils were deformed incrementally using a round-tip single point tool on a desktop type of milling machine controlled with a personal computer. It was found that an aluminum foil 12 mu m thick was much smaller in forming limit than an aluminum foil 50 mu m thick when a single point tool with a tip radius of 0.5 mm was not rotated, but its forming limit was improved greatly by rotating the tool up to 20,000 rpm. Measured forming forces revealed that the tool rotation decreases the in-plane forces by approximately 50%. Hydrodynamic lubrication at the interface between a rotating tool and aluminum foil must have had a direct and favorable influence on the forming process, while increasing the forming limit of the thinner foil. It was also found that the optimum stepwise axial feed was found to be around the value of foil thickness. Then, incremental forming of arrays of dots 0.1 mm in diameter, miniature pyramids, a miniature car and miniature letters was performed successfully under the optimized conditions at arbitrary positions of 12-mu m-thick foils. (C) 2009 Elsevier Ltd. All rights reserved.