Experimental and Simulation investigations of Micro Flexible Deep Drawing Using Floating Ring Technique
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.
Y. M. Huang & Y. S. Wu & J. Y. Huang, “The influence of ultrasonic vibration-assisted micro-deep drawing process”, International Journal of Advanced Manufacture Technology, (2014) 71:1455–1461.
Masoomeh Salahshoor & Abdolhamid Gorji and Mohammad Bakhshi- Jooybari, “The study of forming concave-bottom cylindrical parts in hydroforming process”, International Journal of Advanced Manufacture Technology, (2015) 79:1139–1151.
Ihsan Irthiea, Graham Green, Safa Hashim and Abdulbast Kriama, “Experimental and numerical investigation on micro deep drawing process of stainless steel 304 foil using flexible tools”, International Journal of Machine Tools & Manufacture, (2014) 76:21–33.
Ihsan K. Irthiea and Graham Green, “Evaluation of micro deep drawing technique using soft die-simulation and experiments”, International Journal of Advanced Manufacture Technology, (2017) 89:2363–2374.
Quadrini F, Santo L, Anna E (2010) Flexible forming of thin aluminum alloy sheets. Int J Mod Manuf Technol, II: 79–84.
Balasubramanian Nagarajan, Sylvie Castagne, Zhongke Wang, H.Y. Zheng and Kartikeyan Nadarajan, “Influence of plastic deformation in flexible pad laser shock forming – experimental and numerical analysis”, International Journal of material forming, 1-15.
Liu Y, Hua L, Lan J, Wei X, “Studies of the deformation styles of the rubber-pad forming process used for manufacturing metallic bipolar plates”, J Power Sources, (2010) 195:8177–8184.
C. Kyu, M. Geun, and C. Gil, “Effect of rubber forming process parameters on micro-patterning of thin metallic plates,” Procedia Eng., vol. 81, pp. 1439–1444, 2014.
Wang X, Du D, Zhang H, Shen Z, Liu H, Zhou J, Liu H, Hu Y, Guc, “Investigation of microscale laser dynamic flexible forming process-simulation and experiments”, International Journal of Machine Tools & Manufacture, (2013) 67:8–17.
X. Ma, R. Lapovok, C. Gu, A. Molotnikov, Y. Estrin, E. V. Pereloma, C. H. J. Davies and P. D. Hodgson, "Deep drawing behaviour of ultrafine grained copper: modelling and experiment", Journal of Material sience, vol. 44, pp. 3807-3812, 2009.
R. Lapovok, I. Timokhina, P. W. J. Mckenzie and R. O’donnell, "Processing and properties of ultrafine-grain aluminium alloy 6111 sheet", Journal of Materials Processing Technology, vol. 200, pp. 441-450, 2008.
American Society for Testing and Materials ASTM, “Standard Test Methods for Tension Testing of Metallic Materials,” Am. Assoc. State, pp. 1–27, 2010.
Le Port A, Toussaint F and Arrieux R, “Finite element study and sensitive analysis of the deep drawing formability of commercially pure titanium”. International Journal of material forming, (2009) 2:121–129.
D.V. Hai, S. Itoh, T. Sakai, S. Kamado, Y. Kojima,”Experimentally and numerical study on deep drawing process for magnesium alloy sheet at elevated temperatures”, Materials Transactions, (2008) 49:1101–1106.
Ihsan Khalaf Irthiea, “Process Analysis and Design in Micro Deep Drawing Utilizing a Flexible Die,” University of Glasgow, 2014.
L. Crocker and B. Duncan, “Measurement methods for obtaining volumetric coefficients for hyperelastic modelling of flexible adhesives”, Performance of Adhesive Joints Program, Project PAJex2 - Flexible Adhesives, PAJex2 Report No 3.
Linfa Peng, Peng Hu, Xinmin Lai, Deqing Mei, Jun Ni, “Investigation of micro/ meso sheet soft punch stamping process—simulation and experiments”, Materials &Design, (2009) 30:783–790.
Copyright: Open Access authors retain the copyrights of their papers, and all open access articles are distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution and reproduction in any medium, provided that the original work is properly cited. The use of general descriptive names, trade names, trademarks, and so forth in this publication, even if not specifically identified, does not imply that these names are not protected by the relevant laws and regulations. While the advice and information in this journal are believed to be true and accurate on the date of its going to press, neither the authors, the editors, nor the publisher can accept any legal responsibility for any errors or omissions that may be made. The publisher makes no warranty, express or implied, with respect to the material contained herein.