Characterization of electrically-assisted micro-rolling for surface texturing using embedded sensor

Ng, Man Kwan; Fan, Zhaoyan; Gao, Robert X.; Smith, Edward F.; Cao, Jian

doi:10.1016/j.cirp.2014.03.021

Cited by 30 publications

(5 citation statements)

References 13 publications

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“…For example, Mai et al [ 161 ] fabricated microchannels on 316L‐stainless‐steel sheets using EA microembossing, and the results showed that the channels were deeper and the residual stress was smaller when assisted by electricity. Ng et al [ 162 ] introduced an electric current into microrolling based on texturing in order to increase the depth–width ratio of microchannels. In the recent work, an EA microforming tool with a float die was developed by our research group and microgear structures of TA15 titanium alloy were formed by utilizing flow‐relief hole‐forging methods with a current of 325 A, as shown in Figure 12c.…”

Section: Microforming Processes Of 3d Microstructuresmentioning

confidence: 99%

A Review on Micro/Nanoforming to Fabricate 3D Metallic Structures

Wang

et al. 2020

Advanced Materials

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With the rapid development of micro‐electromechanical systems (MEMS), micro/nanoscale fabrication of 3D metallic structures with complex structures and multifunctions is becoming more and more important due to the recent trend of product miniaturization. As a promising micromanufacturing approach based on plastic deformation, micro/nanoforming shows the attractive advantages of high productivity, low cost, near‐net‐shape, and excellent mechanical properties, compared with other non‐silicon‐based micromanufacturing technologies. However, micro/nanoforming is far less established due to the so‐called size effects in terms of materials models, process laws, tooling design, etc. The understanding of basic issues on micro/nanoforming is not yet mature, and it is currently a topic of rigorous investigation. Here, a systematic review on the micro/nanoforming processes of 3D structures with multifunctional properties is presented, wherein also a critical examination of the interplay between relevant length scales and size effects affecting the structural integrity of micro/mesoscale metallic systems is also provided. Finally, the challenges of micro/nanoscale fabrication are proposed, including the development trends of new micro/nanoforming processes, multiple field coupling effects, and theoretical modeling at the trans‐scale.

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Section: Microforming Processes Of 3d Microstructuresmentioning

confidence: 99%

A Review on Micro/Nanoforming to Fabricate 3D Metallic Structures

Wang

et al. 2020

Advanced Materials

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“…The results showed that the channels were deeper and the residual stress was smaller when the process was electrically assisted. Finally, Cao et al [17] had also induced an electric current during a micro-rolling surface texturing process, in order to increase the depth-width ratio of micro-channels. They found that the channel depths of AA3003-H14 and Ti6Al4V increased by 15% and 200%, respectively.…”

Section: Introductionmentioning

confidence: 99%

Bio-Inspired Functional Surface Fabricated by Electrically Assisted Micro-Embossing of AZ31 Magnesium Alloy

Wang

et al. 2020

Materials

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Developing bio-inspired functional surfaces on engineering metals is of extreme importance, involving different industrial sectors, like automotive or aeronautics. In particular, micro-embossing is one of the efficient and large-scale processes for manufacturing bio-inspired textures on metallic surfaces. However, this process faces some problems, such as filling defects and die breakage due to size effect, which restrict this technology for some components. Electrically assisted micro-forming has demonstrated the ability of reducing size effects, improving formability and decreasing flow stress, making it a promising hybrid process to control the filling quality of micro-scale features. This research focuses on the use of different current densities to perform embossed micro-channels of 7 μm and sharklet patterns of 10 μm in textured bulk metallic glass dies. These dies are prepared by thermoplastic forming based on the compression of photolithographic silicon molds. The results show that large areas of bio-inspired textures could be fabricated on magnesium alloy when current densities higher than 6 A/mm2 (threshold) are used. The optimal surface quality scenario is obtained for a current density of 13 A/mm2. Additionally, filling depth and depth–width ratio nonlinearly increases when higher current densities are used, where the temperature is a key parameter to control, keeping it below the temperature of the glass transition to avoid melting or an early breakage of the die.

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“…When the current density increased to 50 A/mm 2 , the micro-channel depth increased to 26%. Cao et al [32,33] studied the effects of the rolling force and the joule heat and friction on the forming quality of the microstructure by the EA roll forming process. The forming depth and width of the micro-channels increased with the increase of the temperature, rolling force, and friction force.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Electrically-Assisted Rolling Process of Corrugated Surface Microstructure with T2 Copper Foil

et al. 2019

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Electrically-assisted (EA) forming is a low-cost and high-efficiency method to enhance the formability of materials. In the study, EAF tensile tests are carried out to study the properties of T2 copper foil in an annealed state, and the effect of the electric current on the forming quality of corrugated foils is further studied in the EA rolling forming process. The result shows that the current reduces the flow stress and the fracture strain, which is different from the result of rolled samples. The joule heating effect on mechanical properties is significant in EA tension, and the softening effect of the surface layer can be observed at tensile strength, due to the grain size effect. Moreover, the current can weaken the grain size effect. In the rolling forming process, the influence of different electrical parameters on the forming height is remarkable, especially for the rolled T2 copper. The appropriate electrical parameters can improve the forming height, while keeping a small thickness thinning. Nevertheless, the high current density will lead to local rupture. This study proves that the current can improve the forming quality of the corrugated foils and is a promising surface texture forming process.

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Characterization of electrically-assisted micro-rolling for surface texturing using embedded sensor

Cited by 30 publications

References 13 publications

A Review on Micro/Nanoforming to Fabricate 3D Metallic Structures

A Review on Micro/Nanoforming to Fabricate 3D Metallic Structures

Bio-Inspired Functional Surface Fabricated by Electrically Assisted Micro-Embossing of AZ31 Magnesium Alloy

Investigation of Electrically-Assisted Rolling Process of Corrugated Surface Microstructure with T2 Copper Foil

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