Material microstructure and surface considerations in microforming of sheet materials

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The manufacturing of micro-parts has become more important and necessary in many different industrial sectors such as electronics, computers, medical devices and automotive manufacturing. Traditionally these precision mechanical parts are fabricated by machining. The net shape or near net shape processes, such as sheet metal forming processes, are often better suited for miniaturization because of high productivity and cost. The proposed research deals with development of novel micro-forming processes of microbending, micro-draw-bending and deep drawing, micro-shearing and their combined application towards innovative manufacturing of complex micro-features within metallic bipolar plates used in fuel cell stacks. A broader and fundamental understanding of the mechanics of large deformation at the micro-scale will be gained in forming of micro-parts and micro-features within larger parts.