Abstract
Progressive microforming is widely recognized as one of the most efficient and desirable methods of mass production in micromanufacturing arena. To predict the deformation behaviour and size effects of materials induced in progressive microforming, the finite element method (FEM) employed for modelling the microforming process needs to account for microstructure details and deformation/failure mechanisms of the materials. This led to the development of the novel crystal plasticity finite element method (CPFEM) and cohesive zone model (CZM). Previous research and application of CPFEM have been mainly limited to simple deformations such as uniaxial tension and compression, whereas the new method can provide physical insights into how the grain size affects the interplay between crystallographic slip and mechanical twinning in complex microforming, and further material deformation during sheet blanking. A case study was conducted to manufacture a hexagonal socket part using a three-step progressive microforming system, with the comparison between experiments and CPFEM simulations focusing on microstructure evolution, deformation load, and product quality. The CPFEM was found to be more reliable than the conventional FEM in predicting complex deformation, particularly in microstructure and texture evolution, dimensional accuracy and irregular geometries. Results showed that the total height of the part increases with the decreasing grain size, while the head diameter rises with grain size. Simulations successfully anticipated the distributions of dead metal zones and shear bands and identified hole and rollover geometries and corresponding grain size effects. In conclusion, this research facilitates the understanding of grain size effects on the deformation behaviour in progressive microforming and presents a novel approach and strategy for modelling, prediction, and product quality assurance in complex micro deformation and forming processes.
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