Investigation on the roll-to-plate imprinting of metallic surface micro dimples

Abstract

Large-area functional metallic surface microstructures have been increasingly utilized in various industrial fields. As an efficient and economical method in fabricating large-area functional metallic surface microstructures, the roll-to-plate (R2P) imprinting process with the flat die was proposed to experimentally fabricate functional micro dimple arrays on the surface of the metallic substrate. The effects of the rolling direction, die cavity aspect ratio, die feature density and grain sizes on the forming results were investigated using pure copper specimens with different grain sizes. The transfer ratio of surface structures decreases with the increase of the die feature density and die cavity aspect ratio, respectively. The flowing differences of material in the rolling direction and transverse directions lead to the inconformity of section profile of formed dimples in the two directions. The depth of dimples in the rolling direction is prominently greater than that in the transverse direction. The depth difference of dimples in the two directions increases with the increase of rolling depth and reduces with the increase of die cavity width. The surface morphology of formed specimens obviously depends on the material flowing direction, grain sizes and rolling depth. The surface roughness, surface roughness scatter and flatness of the formed specimens increase with the grain size. The symmetry of cross sectional micro hardness distribution on both sides of the formed dimple in the rolling direction is poorer than that on both sides of the formed dimple in the transverse direction. The asymmetry of cross sectional micro hardness distribution on both sides of the formed dimple in the rolling direction becomes more prominent with the increase of grain sizes.