Skip to main content
SpringerLink
Log in

Progressive microforming process: towards the mass production of micro-parts using sheet metal

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Although there is considerable published literature on micro-metal forming processes, there is still a lack of research towards implementing these processes commercially. Some of the challenges are handling of micro-parts and process intermittency. This work demonstrates the feasibility of producing symmetric micro-parts using a progressive forming set-up. Such a progressive forming process alleviates the challenges in handling and removal of micro-parts. Micro-pins with diameters of 0.3, 0.5, and 0.8 mm were successfully manufactured without defects. Experimental observations together with process simulation results showed that this process has three main stages: (1) indentation at the very beginning, (2) upsetting, and (3) extrusion predominantly occurring at the very end stage of the stroke. The bulk of the pin forming occurs at the end stroke of the process (extrusion stage). The effects of punch/pin diameter ratio on the pin aspect ratio and the maximum forming load were also investigated. In addition, the finite element results also revealed that a hybrid friction model was required to be implemented for better fit with experimental results as compared to the shear and Coulomb friction models.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Chinesta F, Cueto E, Engel U, Rosochowski A, Geißdörfer S, Olejnik L (2007) Microforming and nanomaterials advances in material forming. Springer, Paris, pp 99-124. doi:10.1007/978-2-287-72143-4_7

  2. Horiuchi T, Furuuchi Y, Nakamura R, Hirota K (2005) Micro-gear fabrication using optical projection lithography on copper-clad plastic substrates and electroplating of nickel. Microelectron Eng 83(4–9):1316–1320

    Google Scholar 

  3. Ocaña JL, Morales M, García-Ballesteros JJ, Porro JA, García O, Molpeceres C (2009) Laser shock microforming of thin metal sheets. Appl Surf Sci 255(10):5633–5636

    Article  Google Scholar 

  4. Masuzawa T (2000) State of the art of micromachining. CIRP Annals—Manufacturing. Technology 49(2):473–488

    Google Scholar 

  5. Geiger M, Vollertsen F, Kals R (1996) Fundamentals on the manufacturing of sheet metal microparts. CIRP Annals—Manufacturing. Technology 45(1):277–282

    Google Scholar 

  6. Engel U, Eckstein R (2002) Microforming—from basic research to its realization. J Mater Process Technol 125–126:35–44

    Article  Google Scholar 

  7. Okazaki Y, Mishima N, Ashida K (2004) Microfactory—concept, history, and developments. J Manuf Sci Eng 126(4):837–844

    Article  Google Scholar 

  8. Jiang C-P, Chen C-C (2011) Grain Size Effect on the Springback Behavior of the Microtube in the Press Bending Process. Mater Manuf Process 27(5):512–518. doi:10.1080/10426914.2011.593230

    Article  Google Scholar 

  9. Vollertsen F, Hu Z (2006) Tribological size effects in sheet metal forming measured by a strip drawing test. CIRP Ann Manuf Technol 55(Compendex):291–294

    Article  Google Scholar 

  10. Hemker KJ, Sharpe WN Jr (2007) Microscale characterization of mechanical properties. Annu Rev Mater Res 37(Compendex):92–126

    Google Scholar 

  11. Qin Y (2006) Micro-forming and miniature manufacturing systems—development needs and perspectives. J Mater Process Technol 177(1–3):8–18

    Article  Google Scholar 

  12. Jeswiet J, Geiger M, Engel U, Kleiner M, Schikorra M, Duflou J, Neugebauer R, Bariani P, Bruschi S (2008) Metal forming progress since 2000. CIRP J Manuf Sci Technol 1(1):2–17

    Article  Google Scholar 

  13. Sanchez-Salmeron AJ, Lopez-Tarazon R, Guzman-Diana R, Ricolfe-Viala C (2005) Recent development in micro-handling systems for micro-manufacturing. J Mater Process Technol 167(2–3):499–507

    Article  Google Scholar 

  14. Arentoft M, Eriksen RS, Hansen HN, Paldan NA (2011) Towards the first generation micro bulk forming system. CIRP Ann Manuf Technol 60(1):335–338

    Article  Google Scholar 

  15. Engel U, Rosochowski A, Geißdörfer S, Olejnik L (2007) Microforming and Nanomaterials, in Advances in Material Forming, Esaform 10 years on, edited by F. Chinesta and E. Cueto, Springer-Verlag France, Paris. pp 99-124

  16. Hirota K (2007) Fabrication of micro-billet by sheet extrusion. J Mater Process Technol 191(1–3):283–287

    Article  Google Scholar 

  17. Cao J, Krishnan N, Wang Z, Lu H, Liu WK, Swanson A (2004) Microforming: experimental investigation of the extrusion process for micropins and its numerical simulation using RKEM. J Manuf Sci Engineering, Trans ASME 126(Compendex):642–652

    Article  Google Scholar 

  18. Antonio J S (2010) Chapter 18—handling for micro-manufacturing. In: Micromanufacturing engineering and technology. William Andrew Publishing, Boston, pp 298-314

  19. Ghassemali E, Jarfors A, Tan M-J, Lim S (2011) On the microstructure of micro-pins manufactured by a novel progressive microforming process. International Journal of Material Forming:1-10. doi:10.1007/s12289-011-1073-4

  20. P. Robinson (1990) Properties of wrought coppers and copper alloys. In: ASM handbook, vol 2—properties and selection: nonferrous alloys and special-purpose materials. ASM International, Cleveland, pp 265–345

  21. Jeon J, Bramley AN (2007) A friction model for microforming. Int J Adv Manuf Technol 33(Compendex):125–129

    Article  Google Scholar 

  22. Huang MN, Tzou GY (2002) Study on compression forming of a rotating disk considering hybrid friction. J Mater Process Technol 125–126:421–426

    Article  Google Scholar 

  23. Cao J, Zhuang W, Wang S, Lin J (2010) Development of a VGRAIN system for CPFE analysis in micro-forming applications. Int J Adv Manuf Technol 47(9):981–991. doi:10.1007/s00170-009-2135-3

    Article  Google Scholar 

  24. Daw-Kwei L (2009) A simple dry friction model for metal forming process. J Mater Process Technol 209(5):2361–2368

    Article  Google Scholar 

  25. Schey JA (1984) Tribology in metalworking. American Society for Metals, Metals Park

    Google Scholar 

  26. Eriksen R, Weidel S, Hansen H (2010) Tribological influence of tool surface roughness within microforming. Int J Mater Form 3:419–422. doi:10.1007/s12289-010-0796-y

    Article  Google Scholar 

  27. Hou Y, Zhang W, Yu Z, Li S (2009) Selection of tool materials and surface treatments for improved galling performance in sheet metal forming. Int J Adv Manuf Technol 43(9):1010–1017. doi:10.1007/s00170-008-1780-2

    Article  Google Scholar 

  28. Altan T, Oh S-I, Gegel HL (eds) (1983) Metal forming: fundamentals and applications. American Society for Metals, Metals Park

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore, 639798, Singapore

    Ehsan Ghassemali

  2. Singapore Institute of Manufacturing Technology (SIMTech), 71 Nanyang Dr, Singapore, 638075, Singapore

    Ehsan Ghassemali & S. C. V. Lim

  3. School of Engineering, Jönköping University, P.O. Box 1026, 551 11, Jönköping, Sweden

    Anders E. W. Jarfors

  4. School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore, 639798, Singapore

    Ming-Jen Tan

Authors
  1. Ehsan Ghassemali
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ming-Jen Tan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Anders E. W. Jarfors
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. S. C. V. Lim
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Ehsan Ghassemali.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Ghassemali, E., Tan, MJ., Jarfors, A.E.W. et al. Progressive microforming process: towards the mass production of micro-parts using sheet metal. Int J Adv Manuf Technol 66, 611–621 (2013). https://doi.org/10.1007/s00170-012-4352-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-012-4352-4

Keywords

Search

Navigation