Experimental and Simulation investigations of Micro Flexible Deep Drawing Using Floating Ring Technique

Zaid H Mahmood,Ihsan K Irthiea,Kadum A Abed

doi:10.22153/https://doi.org/10.22153/kej.2018.12.007

Abstract

Micro metal forming has an application potential in different industrial fields. Flexible tool-assisted sheet metal forming at micro scale is among the forming techniques that have increasingly attracted wide attention of researchers. This forming process is a suitable technique for producing micro components because of its inexpensive process, high quality products and relatively high production rate. This study presents a novel micro deep drawing technique through using floating ring as an assistant die with flexible pad as a main die. The floating ring designed with specified geometry is located between the process workpiece and the rubber pad. The function of the floating ring in this work is to produce SS304 micro cups with profile radius precision as required as possible. The finite element simulations are accomplished using the commercial code Abaqus/Standard. In order to verify the simulation models, micro deep drawing experiments are carried out using a special set up developed specifically to meet the requirements of the simulations. The results revealed that the proposed technique is feasible to be adopted for producing micro cups with remarkable application capability in miniaturization technology.

Highlights

The increasing demand on micro parts utilized in various industrial fields, including electronics and micro-medical devices get the manufacturers into a competitive situation [1]
This section includes the results that obtained from the experiments of micro deep drawing and validate these results with that obtained by FE simulation under the corresponding conditions
The conditions that adopted in the experiments procedure were as following: punch diameter was 4mm with head radius 0.8mm, Rubber pad diameter was 12mm with height 10mm, initial blank thickness 0.1mm with 10mm as diameter, floating ring thickness was 1mm with shoulder radius 0.75mm and forming velocity was 1mm/s

Summary

Introduction

The increasing demand on micro parts utilized in various industrial fields, including electronics and micro-medical devices get the manufacturers into a competitive situation [1]. Flexible tool-assisted sheet metal forming can be characterized by its feasibility for prototyping processes, simplicity and versatility. F. Quadrini et al [5] studied the effect of die material and its geometry on forming processes of aluminum sheet metal with thickness 150μm. The results showed that using semi-rigid die contribute in production improvement in terms of forming force reduction and die durability. Flexible Pad Laser Shock Forming (FPLSF) process was presented by Nagarajan B. et al [6] to investigate the influence of flexible pad material and its thickness, on the deformation characteristics of different metal foils. It was observed that using rubber material with higher hardness resulted in a reduction in crater depth, foil thickness and the hardness of the crater surfaces. Increasing the flexible pad thickness resulted in an increase in crater depth, thinning but a reduction in surface hardness. Liu et al [7] used rigid

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