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An experimental and numerical investigation on micro rolling for ultra-thin strip

  • Thematic Issue: Flexible forming - Incremental Sheet Forming & Roll Forming
  • Published:
International Journal of Material Forming Aims and scope Submit manuscript

Abstract

The demand for miniaturized parts and miniaturized semi-finished products is increasing nowadays, because microforming processes can improve production rate and minimize material waste due to less forming passes. However, traditional macro metal forming processes and modelling cannot be simply scaled down to produce miniaturized micro parts. In this study, a 2-Hi micro rolling mill has been successfully built. Experimental and numerical investigations on the micro rolling process for ultra-thin SUS 304 stainless steel strip have been conducted. The experimental results show that the micro rolling deformation of ultra-thin strip is influenced by size effect which results from the specimen size difference and this size effect is embodied in the flow stress and the friction coefficient. Analytical and finite element (FE) models in describing size effect related phenomena, such as flow stress, friction, rolling force and deformation behaviour, are proposed. The material surface constraint and the material deformation mode are critical in determination of material flow stress curve. The analysis of surface roughness evolution with rolling conditions has also been performed. The identified analysis on deformation mechanics provides a basis for further exploration of the material behaviour in plastic deformation of micro scale and the development of micro scale products via micro rolling.

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Acknowledgments

The authors would like to give thanks to Prof. Yoshino of Tokyo Institute of Technology and Prof. Koyama of Chiba University. The first author is grateful to the Japan Society for Promotion of Science (JSPS), Japan for awarding of JSPS post-doctoral fellowship (FY 2012–2014) to carry out research in Japan and the support from Australian Academy of Science (AAS). This research was supported by the Grant-in-Aid for JSPS Fellows relating to JSPS Post-doctoral Fellowship for Foreign Researchers (Grant No. 24.02770) from JSPS.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Tokyo Metropolitan University, Tokyo, 192-0397, Japan

    H. B. Xie, K. Manabe, T. Furushima & K. Tada

  2. School of Mechanical, Materials and Mechatronic Engineering, University of Wollongong, Wollongong, NSW, 2522, Australia

    H. B. Xie & Z. Y. Jiang

Authors
  1. H. B. Xie
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  2. K. Manabe
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  3. T. Furushima
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  4. K. Tada
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  5. Z. Y. Jiang
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Correspondence to H. B. Xie.

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Xie, H.B., Manabe, K., Furushima, T. et al. An experimental and numerical investigation on micro rolling for ultra-thin strip. Int J Mater Form 9, 405–412 (2016). https://doi.org/10.1007/s12289-015-1229-8

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  • DOI: https://doi.org/10.1007/s12289-015-1229-8

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