Abstract
This study aims at making a small billet for micro forging from sheet metals. Disk specimens were made form 2 mm thick aluminum sheets and extruded in the thickness direction at an extrusion ratio of 2. A billet of 1 mm in diameter was successfully formed on the specimen and the billet height varied from 2 to 5 mm depending on constraining conditions of specimen. The highest billet was obtained when the specimen was extruded with both the top and side faces constrained. Diameter of specimen also affected the billet height in the case of no constraint in the radial direction. Deformation behavior was studied by FE analysis and difference in metal flow by the constraining conditions was clarified. Strain distributions showed that deformation became severe toward the bottom of the billet. Piping defects that occurred in the end of forming were also predicted. Calculated billet heights agreed well with the measured ones.
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