Investigation on Dimensional Accuracy in Micro Cross Wedge Rolling of Metals

2014 ◽  
Vol 622-623 ◽  
pp. 943-948 ◽  
Author(s):  
Haina N. Lu ◽  
D.B. Wei ◽  
Z.Y. Jiang
Keyword(s):  
Size Effect ◽  
Material Flow ◽  
Pure Copper ◽  
Dimensional Accuracy ◽  
Material Consumption ◽  
Cross Wedge Rolling ◽  
Cross Sectional ◽  
Geometrical Accuracy ◽  
Element Simulation ◽  
Micro Parts

A novel microforming process - Micro Cross Wedge Rolling (MCWR) has been developed. It is a very promising technology in the field of microforming due to its advantages such as high product rate and minimised material consumption. How to control geometrical accuracy of the produced micro parts is one of the major challenges in the development of microforming technology. Geometrical accuracy was still concentrated in term of springback. When the wedge tools loads are removed after forming step, a portion of the deformation recovers, which causes a change in the shape of micro parts. In other word, springback happens, which should be determined and controlled especially in microforming technology. A series of MCWR experiments of pure copper and aluminium have been carried out using the machine designed by authors in this study. Cylindrical workpieces were deformed into stepped shafts with cross-sectional area reductions of 35, 52.73 and 75%. Corresponding finite element simulation has also been conducted in consideration of the size effect on the material flow. The springback was proposed to account for the geometrical error of micro products. The effect of grained heterogeneity on the height of surface asperity after rolling was assessed quantitatively. Keywords: Micro cross wedge rolling, Size effect, Dimensional accuracy, Springback

Investigation of Microstructure and Hardness in Microfoming of Pure Copper Pins

2010 ◽  
Vol 447-448 ◽  
pp. 381-385
Author(s):  
Ehsan Ghassemali ◽  
Anders W.E. Jarfors ◽  
Ming Jen Tan ◽  
Samuel C.V. Lim ◽  
Mei Qian Chew
Keyword(s):  
Mechanical Properties ◽  
Material Flow ◽  
Strain Distribution ◽  
Pure Copper ◽  
Extrusion Process ◽  
Optical Microscope ◽  
Gradient Distribution ◽  
Micro Scale ◽  
Part Geometry ◽  
Micro Parts

Microforming is defined as the process of production of metallic micro-parts with sub-millimeter dimension. There is as strong interaction between the scale of the microstructure and the size of the part affecting material flow, the so-called “size effect” in microforming processes. Conventional forming rules cannot be directly applied to the micro-scale forming. To better understand the implications for part geometry and properties, further investigation of the material flow related events is necessary. The aim of this work is to investigate microstructural evolution of pure copper during a micro-extrusion process - for production of micro-pins with diameters varying from 300 to 800µm - by means of optical microscope (OM). Qualitative strain gradient distribution could be observed by those pictures. The results showed that change of micro-pins diameter and die angle affect the microstructure and strain distribution of the final product remarkably, that affect the mechanical properties of the pin formed. Furthermore, microhardness results were consistent with the microstructural observations.

scholarly journals A Review of Progressive and Compound Forming of Bulk Microparts by Using Sheet Metals

2018 ◽  
Vol 190 ◽  
pp. 01001 ◽  
Author(s):  
M.W. Fu ◽  
J.Y. Zheng ◽  
B. Meng
Keyword(s):  
Size Effect ◽  
Sheet Metal ◽  
Material Flow ◽  
Dimensional Accuracy ◽  
Promising Method ◽  
Sheet Metals ◽  
Forming Process ◽  
Geometrical Feature

In the last decade, the concept of progressive microforming has emerged and developed gradually, which is considered as an efficient and promising method to fabricate the micro-scaled part. Micro-cylinder parts, micro-flanged part, and multi-flanged microparts are representative micro bulk parts by the progressive microforming system using sheet metal. In these cases, many efforts focus on the forming process, such as microblanking and microextrusion. Meanwhile, the quality of the fabricated parts also attracts attention. In this paper, an intensive review on the development of progressive microforming technologies and the formed parts is presented, and the influence of size effect to dimensional accuracy, material flow, geometrical feature, and fracture is also discussed.

A reciprocating permanent magnetic actuator for driving magnetic micro robots in fluids

2021 ◽  
pp. 095440622110145
Author(s):  
Chuan Qu ◽  
Yong-Chen Pei ◽  
Qing-Yuan Xin ◽  
Zhen-Xing Li ◽  
Long Xu
Keyword(s):  
Permanent Magnet ◽  
Analytical Calculation ◽  
Magnetic Actuator ◽  
Cross Sectional ◽  
Permanent Magnetic Actuator ◽  
Element Simulation ◽  
Micro Robot ◽  
Analytical Formulas ◽  
Motion Performance ◽  
Motion Characteristics

Magnetic-based driving applications are receiving increasing attention. This study proposed a novel reciprocating permanent magnetic actuator (PMA) to manipulate magnetic micro robots to impact and clear blockages inside fluid pipes in a linear path. The PMA consisted of a cylindrical permanent magnet and a crank slider structure. A straight pipe with a circular cross-sectional area was located in front of the actuator to study the driving performance of PMA. A micro permanent magnet with a cylinder shape was employed as a working robot for manipulation inside the pipe. Firstly, analytical formulas were derived to obtain the magnetic driving force acting on the micro robot and determine the most suitable magnet configuration. The finite element simulation verified the analytical calculation. The developed reciprocating PMA prototype was then introduced, and the PMA and micro robot’s motion performance was analysed. Lastly, preliminary experiments were carried out for evaluating the micro robot’s motion characteristics. Performance tests for different excitation frequencies, flow rates, viscosities, and axial distances, indicating that PMA could manipulate the magnetic micro robot inside the pipe. The results confirmed that the developed PMA could effectively drive the micro robot with the advantage of consecutive magnetic driving. Especially, the micro robot featured good flexibility, rapid response, and a simple structure, suggesting that this micro robot may play an important role in industrial and medical applications, such as blockage elimination and thrombus clearance.

In Implementing a Metal 3D AM Machine

2018 ◽  
Vol 786 ◽  
pp. 356-363
Author(s):  
Tero Jokelainen ◽  
Kimmo Mäkelä ◽  
Aappo Mustakangas ◽  
Jari Mäkelä ◽  
Kari Mäntyjärvi
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Dimensional Accuracy ◽  
Acceptance Test ◽  
Aisi 316L ◽  
Laser Melting ◽  
Geometrical Accuracy ◽  
Machine Performance ◽  
Geometrical Features ◽  
Made In

Additive Manufacturing (AM) does not yet have a standardized way to measure performance. Here a AM machines dimensional accuracy is measured trough acceptance test (AT) and AM machines capability is tested trough test parts. Test parts are created with specific geometrical features using a 3D AM machine. Performance of the machine is then evaluated trough accuracy of test parts geometry. AM machine here uses selective laser melting (SLM) process. This machine has done Factory acceptance test (FAT) to ascertain this machine ́s geometrical accuracy with material AISI 316L. Manufacturer promises accuracy of ±0.05 mm. These parts are used as comparison to AT parts made in this study. After installation two AT parts are manufactured with AM machine. One with AISI 316L and one AlSi10Mg. Dimensional accuracy of geometrical features on these parts are then compared to FAT part and to one another. Machines capability is measured trough two test parts done with material AlSi10Mg. Two of the test parts are done at the same time using same model as the FAT. Parts are printed without supports and with features facing same directions. Features of these parts were then evaluated. Another test to find out AM machines capability was to create part consisting of pipes doing 90˚ angle resulting in horizontal and vertical holes. Dimensional accuracy and circularity of holes was measured. Through these tests machines capability is benchmarked.

Material Flow Estimation of Deep-Drawn Product by Using Finite-Element Simulation

2011 ◽  
Vol 301-303 ◽  
pp. 452-455 ◽  
Author(s):  
Yuji Kotani ◽  
Hisaki Watari ◽  
Akihiro Watanabe
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Finite Element Simulation ◽  
Material Flow ◽  
Thickness Distribution ◽  
Sheet Thickness ◽  
Original Material ◽  
Element Simulation ◽  
Thickness Prediction ◽  
Simulation And Evaluation

The approach to total weight reduction has been a key issue for car manufacturers as they cope with more and more stringent requirements for fuel economy. In sheet metal forming, local increases in product-sheet thickness effectively contribute to reducing the total product weight. Products could be designed more efficiently if a designer could predict and control the thickness distribution of formed products. This paper describes a numerical simulation and evaluation of the material flow in local thickness increments of products formed by an ironing process. In order to clarify the mechanism of the local increase in sheet thickness, a 3-D numerical simulation of deep drawing and ironing was performed using finite-element simulation. The effects of various types of finite elements that primarily affect thickness changes in original materials and thickness prediction were investigated. It was found that the sheet-thickness distribution could be predicted if the original material was relatively thick and if an appropriate type of finite element is selected.

Additive manufacturing using fine wire-based laser metal deposition

2019 ◽  
Vol 26 (3) ◽  
pp. 473-483
Author(s):  
Muhammad Omar Shaikh ◽  
Ching-Chia Chen ◽  
Hua-Cheng Chiang ◽  
Ji-Rong Chen ◽  
Yi-Chin Chou ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
High Precision ◽  
Surface Finish ◽  
Dimensional Accuracy ◽  
Laser Metal Deposition ◽  
Cross Sectional ◽  
Content Type ◽  
Fine Wire

Purpose Using wire as feedstock has several advantages for additive manufacturing (AM) of metal components, which include high deposition rates, efficient material use and low material costs. While the feasibility of wire-feed AM has been demonstrated, the accuracy and surface finish of the produced parts is generally lower than those obtained using powder-bed/-feed AM. The purpose of this study was to develop and investigate the feasibility of a fine wire-based laser metal deposition (FW-LMD) process for producing high-precision metal components with improved resolution, dimensional accuracy and surface finish. Design/methodology/approach The proposed FW-LMD AM process uses a fine stainless steel wire with a diameter of 100 µm as the additive material and a pulsed Nd:YAG laser as the heat source. The pulsed laser beam generates a melt pool on the substrate into which the fine wire is fed, and upon moving the X–Y stage, a single-pass weld bead is created during solidification that can be laterally and vertically stacked to create a 3D metal component. Process parameters including laser power, pulse duration and stage speed were optimized for the single-pass weld bead. The effect of lateral overlap was studied to ensure low surface roughness of the first layer onto which subsequent layers can be deposited. Multi-layer deposition was also performed and the resulting cross-sectional morphology, microhardness, phase formation, grain growth and tensile strength have been investigated. Findings An optimized lateral overlap of about 60-70% results in an average surface roughness of 8-16 µm along all printed directions of the X–Y stage. The single-layer thickness and dimensional accuracy of the proposed FW-LMD process was about 40-80 µm and ±30 µm, respectively. A dense cross-sectional morphology was observed for the multilayer stacking without any visible voids, pores or defects present between the layers. X-ray diffraction confirmed a majority austenite phase with small ferrite phase formation that occurs at the junction of the vertically stacked beads, as confirmed by the electron backscatter diffraction (EBSD) analysis. Tensile tests were performed and an ultimate tensile strength of about 700-750 MPa was observed for all samples. Furthermore, multilayer printing of different shapes with improved surface finish and thin-walled and inclined metal structures with a minimum achievable resolution of about 500 µm was presented. Originality/value To the best of the authors’ knowledge, this is the first study to report a directed energy deposition process using a fine metal wire with a diameter of 100 µm and can be a possible solution to improving surface finish and reducing the “stair-stepping” effect that is generally observed for wires with a larger diameter. The AM process proposed in this study can be an attractive alternative for 3D printing of high-precision metal components and can find application for rapid prototyping in a range of industries such as medical and automotive, among others.

Finite Element Simulation of Aluminum ECAP Material Flow

2013 ◽  
Vol 423-426 ◽  
pp. 267-270
Author(s):  
Jian Hui Li ◽  
Zu Jian Yu ◽  
Da Zhi Xiao ◽  
Li Ping Zhang
Keyword(s):  
Finite Element ◽  
Material Flow ◽  
Maximum Principal Stress ◽  
Metallic Materials ◽  
Rigid Plastic ◽  
Ecap Processing ◽  
Angular Pressing ◽  
Fine Grain ◽  
Corner Flow ◽  
Element Simulation

To enhancing strength and toughness of metals, severe plastic deformation (SPD) grain refinement was a typical method. As one of the SPD method, equal channel angular pressing is an effective method in fabricating ultra-fine grain metallic materials. In this paper, the rigid-plastic finite element method was used to analyze the aluminum alloy ECAP processing, to reveal the material flow character and its effect on microstructure evolution. The simulation results were agreed with plastic mechanics and experiment well, and it was shown that distribution of maximum principal stress was not uniform, material located at the front-end of sample flow easily and material located at the top of die channel corner flow difficultly.

scholarly journals Size Effect on Mechanical Properties and Deformation Behavior of Pure Copper Wires Considering Free Surface Grains

Materials ◽  
2020 ◽  
Vol 13 (20) ◽  
pp. 4563
Author(s):  
Yu Hou ◽  
Xujun Mi ◽  
Haofeng Xie ◽  
Wenjing Zhang ◽  
Guojie Huang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Free Surface ◽  
Size Effect ◽  
Single Crystal ◽  
Deformation Behavior ◽  
Pure Copper ◽  
Critical Value ◽  
Wire Diameter ◽  
Surface Model

The size (grain size and specimen size) effect makes traditional macroscopic forming technology unsuitable for a microscopic forming process. In order to investigate the size effect on mechanical properties and deformation behavior, pure copper wires (diameters range from 50 μm to 500 μm) were annealed at different temperatures to obtain different grain sizes. The results show that a decrease in wire diameter leads to a reduction in tensile strength, and this change is pronounced for large grains. The elongation of the material is in linear correlation to size factor D/d (diameter/grain size), i.e., at the same wire diameter, more grains in the section bring better plasticity. This phenomenon is in relationship with the ratio of free surface grains. A surface model combined with the theory of single crystal and polycrystal is established, based on the relationship between specimen/grain size and tensile property. The simulated results show that the flow stress in micro-scale is in the middle of the single crystal model (lower critical value) and the polycrystalline model (upper critical value). Moreover, the simulation results of the hybrid model calculations presented in this paper are in good agreement with the experimental results.

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