Abstract
Press forging is a method for forming bosses by extruding a thin sheet metal into small holes of a die. Bosses formed on cases made of a light sheet metal make it possible to decrease the weight of mobile devices, for example, mini-disc players and digital cameras. However, when the material is too thin, dimple defects often appear on the reverse surface of the boss, which becomes the design surface, shortly after the beginning of the forming process. In this study, we investigate the deformation properties of bosses and dimples by experimental observations and finite element analysis, and methods for preventing dimple generation are described. When a boss is formed with a diameter of 5 mm on a sheet metal with a thickness of 1.2 mm, the maximum boss height without dimple defects is improved from 0 to 2.5 mm.
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