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The micro metal forming manufacturing system is essentially an ultra precision forming press that can manufacture various micro scale products from metal thin foil and bulk material. In this paper, the micro metal forming manufacturing system has been developed using a micro servo motor. A micro forming system has been developed in Japan with a micro press that is limited to the single forming process. However, a press with a multi forming process is needed and we set about performing research and development of assorted equipment, including investigation into micro deep drawing and the micro punching process. In order to achieve this goal, exploration into the micro forming process as related to the multi forming process must be preceded first. Material selection and analysis of the micro forming process are accomplished in this paper, and the basis research as to how to make the actual system is accomplished.

A micro-alloyed non-heat-treated material does not need post heat treatment processes such as quenching and tempering after the forming process in production stages. This material can be called a green material since it can reduce industrial costs and harmful pollutants generated from post heat treatments. In this paper, near-net-shape forming processes were studied in order to make an automotive part using a micro-alloyed material. The cold forging technique using a former was utilized for the main shaping, and the cold incremental forming technique using a cross wedge rolling machine was adopted for the enhancement of strength and the final shaping of the part. In order to get more adequate process, the cross wedge rolling process is compared to the swaging process for the micro-alloyed steel and general carbon steels through experiments.

High precision micro screws have been widely required for the fastening parts of electronic storage devices. Teeth’s forming of the micro screw is generally utilized by a cold thread rolling process with a flat die. This process for micro sized parts has some difficulties such as the design of die shape, alignment between dies, and process managements. In this paper, it is focused on the effect of the alignment between dies and material, and process parameters in simulation. The investigated parameters are the friction coefficient and the relative position between stationary and moving dies using a numerical simulation. The simulations provide that the shear friction factor of 0.9 is proper for preventing slip between dies and raw material and the relative position of two dies has to be set to the half length of the pitch for maintaining the continuous thread profiles. The deformed shapes of the pitch part and the top part of threads can be demonstrated the feature of experimental result. The folding phenomenon appeared at the top part of threads, which seemed to be induced by a lack of the metal flow under micro sized deformation.