Numerical Simulation in Microforming for Very Small Metal Elements

Abstract

Microforming is a technology of very small metal elements production, which are required as a parts for many industrial products resulting from microtechnology. This chapter gives a review of the state-of-the-art microforming of metals and its numerical simulations. Phenomena occurring in the miniaturization of microbulk-forming technologies are described. The main problems in microforming are size effects, which have physical and structural sources and directly affect the material flow mechanics in microscale. Size effects must be taken into account in all areas of the forming process chain, demanding new solutions, especially in workpiece structure and die surface numerical modeling.

Comparative analysis of parameters affecting micro-forming process

“…As a result, the material contains more grains, which can act as barriers to the propagation of cracks, making it harder for a fracture to occur. [3], [11].…”

“…By understanding the impact of t/d ratio on the fracture behavior of a material, engineers can choose the appropriate material and optimize the sample geometry to ensure the highest possible fracture resistance.Material yield occurs when all the grains in a portion give, and the first yielding occurs in the weakest area, which typically contains the soft grains. The less the number of grains in the section, the more likely it is to include a significant proportion of soft grains, which reduces fracture strain [3], [12].…”

“…Therefore, it is critical to process microscopic components employing integrated micro forming, which contributes to improving tribological characteristics, product precision, and work material formability. Due to micro size constraints, the effect of deformation characteristics in micro forming [2], [3]. The grain size of the specimen, workpiece size, workpiece shape, and component feature size are the major four factors that affect material deformation.…”

“…The stability of the micro-forming model, the deformation load, the deformation defect, the dimensional accuracy, the surface polish, and the mechanical characteristics of the deformed microparts (specimen) are all factors that affect the quality of the micro-formed material and how well the system works [3]. The most significant advantage of micro-parts manufacturing is the capacity to make goods with feature sizes of less than 100m.…”

“…Size impact refers to the perception of unpredictability in process parameters while treating similarly scaled workpieces. These factors separate the presented technique from conventional metal-forming forming processes and substantially impact the potential and limits of this technology [3], [4].…”