ArticlePDF Available

Development of a new machine system for the forming of micro-sheet-products

DOI:10.1007/s12289-008-0098-9
Authors:
Yurong Qin at Guangxi University
Yurong Qin
Y. Ma
Y. Ma
Y. Ma
  • This person is not on ResearchGate, or hasn't claimed this research yet.
Colin S Harrison at Glasgow Caledonian University
Colin S Harrison
A. Brockett
A. Brockett
A. Brockett
  • This person is not on ResearchGate, or hasn't claimed this research yet.
Show all 10 authorsHide
Download full-text PDF
Read full-text
Download citation

Abstract

Challenges concerning industrial applications of microforming have been recognised, and efforts are being made to meet these challenges. For micro-sheet forming, fundamentals related to the development of an industrial system are being examined further by the EU MASMICRO consortium, based on which prototype micro-sheet-forming machine system has been developed. The system development addresses the specific issues concerning machine dynamics, material feeding, production rate, tool design and fabrication, and part transport. The prototype system has been tested with the forming of demonstration components and an industrial version of the machine has been designed.
Content uploaded by Colin S Harrison
Author content
All content in this area was uploaded by Colin S Harrison
Content may be subject to copyright.

   ! 
 ! !"# # 
$#  #  "  !
"! !%# $# $$ "
!%# &"# '  "$ "
 " $" $#  (
)  *" ! 
!! "  )  
+ "  "!  
%#   ") , 
$%$--.!)!$"
%$/01'
" $ $  "$
"  -(  
!  " !(# " ) 
!% ""$"&(
" /231' 4 " "$
!#  ")$ 
!-!!# ("$
""55&
!"*"-,
67   "   ) 
"- 6  "$
# ("!-(
"78
6-7 !$"!
   " )
 !+8
67 !$!(!
 ! #   " 
!"$("8
6!7"- - 6"#
#-(#$#'7!8
67  "  "$ + # !
%   ! !$ 
9)& 8
6"7 4!!$ $-& ! !$ !
$ )&# "# -# '
! )  "$ " %(  
'
!% ! "
% (   :; : 4
6
)))''7#!!-(%(
"(!'
4<4, $ $ !  " "$ % - $!# !
""  -$ !   $' "$# "! ! 
!% "!(-$9!"-(4#-!
 ) (  "$  ( - !% !'  ( !% 
!! "$!(#"!$# !#!$!
"-# !  '  (  ( - ! )  "$ " !
!!%"-!$!'
=()!,"$#"$#"$(#!$
>% ")(""$"
!
?' @
# ?' 
# '
# 4' <&
# ' A
# B' A
# ' C)
# 4' *
# '

D
#B'$
E

 !!!"#$!%%! &% '!( !!"#
)
*!+,-./
 !0%!% &% 11( 0%!%
,
2".##)34335/65*7860
 !##! &% 9"( ##!
D4>>4
 ( - "! $
%# $  ) ( -
! $!!  ( "  "
"  ) !
/1'(-%-$$
!(!$!!"-!"$!
$!'  "  * 6-( 
7 ( - - ) )(!
 ! !$# ( "
"$ # '$' $ 
 ! * # -!
) (! ! "($
# ' "$ ( -
""! ) ' 
 $("  *#
! " %# $
'  !%  " ( " 
! $"  " 
!$  "" (' F ) 
% - 9 ! !$ ! "- 
 ( ' 4 ( " -
 " "$ ) %!!  
/01'
 .#!% $!
!( - "'  ")$ 
!! "  !%  "  
"$(,!$$
"$" 6&5578
!!$-( !$
"  " ) # $!# "!#
#$!)& #"!!8
 * "" $  # 
"!$# $!$ ! !$ 6!$  "$7#
# !$#  # '8
- $ " " ! !  "
8-"(! 8
%( "!(# -( # )
+ "!('
E4?>FC:
,!%
  ( $ "  !% # %
"  ) !! !
9!  !'   ) - 
G H " # -! 
% !( "   !
!( # ! #
%-( "  )& # '  
!(.#!$"
$ ! $   -( 
!$ !  !  -) 
!-9 !'()
! 9   "+( " 
 ( 6$' 7 ! !(  
"$!")-.!
$ ! $'  ( %!
" " "  !$ "  #
$!&(-(#$9
!( " -$ !! " 
 (' ! $ ! )&$
!6 555 $7#
(-'
,!).0%
")& 
"$)""(!!$!$
)  ! !'   
(   !# !$
'"&(!% !
 ) +" " !(
 " $ 6$' D7'
% $" "" 
" !  "' )
.""$#!"$(
"  #  ( "  '
>( ( ! 9   )
"! "   " !
!' (# !(
  "   !  -& ! )
9! "(# ! !  
 !$ "$'  &( "!$ !
!(!  ) !  !
!  # ) !  
$'!(()
!$ ((!$"
!""" ! '
  ) !$! ) 9 " 
-&!67 ) % $"   
"$ "    6 (#
!$ $# !$  !  "7'
 ) "! 9  !$
""% $ % " 
!%  " !" !  % "
"$+('!% !!)
%(!$!!$!
!$ " ' $' E 
"!!% !'

,!,
!$  $  ! ) $
( $  "$' 4
 "! ! % "! ) 
 " $!$ ) ! " 
"!$ "   6 # -# -
!7#&"))
-) D5  55 ' !$  "
555 %!'4"!$("5
E5  %-# ! !$   ! !
"!$ !' %$  
( "  "!$ %! -( $
'4)#!% "!
-$ !% !# )  -.% " %$
"!$6"!7"0'
,!:*0;.0&
.
.0&
.
!$
!% !
%("(!" $"!
!("!'4 
 ( ! ! !  
-$ "!' " I )  
($!" '$( 
"  "-'  ($ 
"! )
! # ! !#   (
!% !'  $ "   "
$  "  $  -$
"!# ) %! )  
$ !   -$ (! )
 % "    !
"!$ $'
,!+.%%;2<1&
&2%
.
4(2<1&
&2%
.
-
!% !6$'27!-$"!'
!%-(!6DJ&K 7'
 ( "" ! 9'
"+( " 555 # 9' " " 0'E &#
%"5' L6$7# !
!"5''
( -  $"$ "
 6 " D5 55 
&7'  9 )&$  "
2559255#)"9- '
!%$" )( $-#)
! " $$    ' 
"!  $ ( 
- " "  )  !
! )#!-!
! " ) !   ! )
% !  -)   ! 
!'
2 ?F4C>4
 "$ " !  6
 7 ) !   "$ 
( ) )(!% ! $$ !
$ $ '   "
# - $ "
$# $# + ! # ) !
" -&$  !"" (  "
$
$
$'D49" " 
$'E4""$
' 4 $ 6 "%$
$% ! !$7 ) !% ! " 
"$" $!)#
)!! $#-&$!-!$
" D0 ! 05  &   6!! !
 ! $- #  ! 
! !-7') !
"  !!)$'0'
$ !$ !! -( 
"!$#  !  "
%! '   ( )
!   " ;5# 55# D55# E55 ! 555
' :#  !  )
% $  ' 4 "  
"$ "  " &$$
(# !$! -(  4 
6%%$ $# -&$# -!$ ! !
!)$7-$ !#"-$
 % "  +( "  -
!!'
0C
 (  " )  ( " 
"$ 62<1&
&2%
.
7
 -
!% !# )   ! !$
'  !%  -! ) %
%% !$  ! )& 
!$# ) " ! "
$!%'(
- ! )  "$ " %
!'!% !
(  - ! " "$
# ) % !$' 4 "
$  !%   ! !$ "
#!-(!&&# '
!$)%-!'
4=K C>
 "   " !$
   M$ " "$ ( "
" " :!
647N 6:DD5520555O07 &)!$!'
! 9  ! &)!$ )  4
   ! !%  (
&)!$!'

' '$#'=#'&#'!'$#
G"$H# 4 " : 05 6D7 6D557 220 
2;D'
D' 'F#A'#'*""!'#
 "   "$ ! %$ 
!!)$'B'':''#06D552735
3O'
E' '$!'!"#G"$$(
)(! H#=( #:'
 ' "'  "$# -
$#4#'D55;# 'DE5
2'  # *9 . 0
6D552D5537#:DD5520555O0'
0' ?' @# M"$ !  "$
(>% !!  %N#=(
 5! =!  2%# ' D55;# B'
':''#336D55;7JJ'
;' ?' @# M>%  "  $! "$
"( " " " 
!N# =( #:' ' "' 
"$# -$# 4# ' D55;#
'E025'
3' ?' @# M4!%  "$  !
$ !% # ! $ 
"  $N# =( # 
$$D553##%'D553#J'
$'0) !"
"!
$'2!"("
"$2<1&
&2%
.
... Pengembangan mesin micro-press yang pernah dilakukan oleh peneliti lain diantaranya adalah Groche, et al. [15] membuat prototipe mesin micro-forming dengan kapasitas maksimum 20 kN dan kecepatan maksimum 1200 spm (stroke/minutes). Selain itu, Flexible µ-Forming berkapasitas 5,3 kN pernah dikembangkan oleh Y. Qin, et al. [16] yang dilengkapi dengan alat ukur gaya proses beresolusi sebesar 0,1 N. Presz et al. [17] mengembangkan mesin micro-forming dengan kapasitas 5 kN dengan penggerak piezoelectric, sementara Arentoft, et al. [18] menggunakan aktuator servo motor untuk mesin micro-forming nya berkapasitas 50 kN. Sedangkan, Jie Xu, et al. [1] mengembangkan mesin micro-forming dengan kapasitas 8,8 kN dengan kecepatan stroke maksimum 1,1 m/s, dan mampu beroperasi pada kecepatan minimum sebesar 5 µm/s dengan resolusi posisi 0,12 µm. ...
DESAIN DAN PENGEMBANGAN MESIN MICRO-PRESS PEMBENTUK KOMPONEN MIKRO
Article
Full-text available
  • Dec 2022
The increasing application of micro electro mechanical systems technology on daily life devices increases the need for micro components. Furthermore, it must be supported by reliable fabrication technology to produce micro-sized products. One of these technologies is micro-sheet metal forming, which is a forming technology from sheet metal with 10-300µm thickness. The development of this technology requires a special press machine that is used in the scope of micro-scale work, named micro-press. Micro-press is still rare due to it was used for individual experiment purposes. Thus, it is necessary to develop the micro-press to support research and manufacturing of micro-part. In this study, the design of a micro-press is intended to accommodate the miniaturization problems and to be easy in fabrication and re-fabrication. Then, the micro-press will contribute to fulfill the micro-parts need. By using the VDI 2222 design method, the design of a 5kN micro-press machine with a servo motor drive is obtained, and validation of construction strength was carried out with the help of the appropriate CAE software. The results of the design validation show that the construction of the micro-press machine is quite strong. The selected component has a strength specification that is greater than required, and the maximum stress that occurs in the frame, which is 80.096 N/mm2, is still very lower than the allowable stress on the SPHC material. The magnitude of the resultant displacement shows a fairly small value, i.e. 0.178 mm.
View
... According to a previous work [1], a reduction of 1/10 in a production plant due to the micro-machining adaptation could provide a 1/100 of cut in the energy consumption. The most impressive advantage of the micro-machining operations is to produce such a small dimension that almost same with a hair size [2,3]. ...
Micro-milling operation of UHMWPE composites with PTFE and aramid reinforcements
Article
Full-text available
Compression molded polymer composites are generally produced with small dimensions for advanced engineering applications such as microelectronics. Among a broad range of polymers, ultra-high molecular weight polyethylene (UHMWPE) rises as an excellent matrix material due to its high impact absorbing, advanced wear resistive, low friction, self-lubricating, anti-corrosion and eco-friendly properties. Although UHMWPE based composites have been widely investigated in terms of tribology, impact behavior and mechanical properties, there is a big gap in literature regarding the micro-machinability of these advanced composites. In this work, polytetrafluoroethylene (PTFE) and aramid reinforced UHMWPE composites were produced in a compression molding chamber and these specimens were subjected to micro-milling operations by using a flat micro end cutter at three different spindle speeds. Micro-machining characteristics were evaluated in terms of surface roughness and cutting temperature. From the results, surface quality is heavily affected by spindle speed, which changes the material removal mechanism from tearing to shearing at higher rates. Molding pressure is also determinant on surface roughness by means of microstructural consolidation. Regarding the filler materials, it is possible to state that there are two different roughening mechanisms after milling. In the PTFE filled composites, machined surfaces include pitting topographies due to the detached particulate PTFE. However, fiber protrusions from the matrix enhance the roughness on the machined surfaces of the aramid reinforced composites. Furthermore, filler inclusions lead to a slight increase in the cutting temperatures during the milling operations.
View
... Okazaki et al. [14] showed the effect of miniaturization and stated that a reduction of 1/10 of the production facility can result in a reduction of energy consumption of 1/100 compared to the energy consumption. The most remarkable development in micromachining is the ability to produce components with a characteristic size of 100 µm, close to the size of human hair [15]. Micromanufacturing applications for micromachining are divided into micromilling [16], microturning [17], and microdrilling [18]. ...
Optimization of micromachining operation for particle reinforced UHMWPE composites
Article
Unlike metals, polymers are highly affected by the heat generation during the machining of the workpiece, because the thermal conductivity of polymers are considerably lower than metals, and therefore heat is much more effective in the cutting zone. If the appropriate cutting parameters are not selected, the polymers become excessively deformed and the final part has high surface roughness, dimensionally large burr formation, or dimensional deviations. Machining of polymers ultra-high molecular weight polyethylene (UHMWPE) is quite common in industrial applications. In this study, the effect of SiC fillers on the machinability of UHMWPE polymer composite was investigated. First, different samples were produced using different filler sizes (1 µm, 50 µm, and 100 µm) and different filler amounts (1%, 3%, 5%). Micro-milling tests were carried out at a constant feed rate (70 mm/min), constant cutting depth (0.1 mm) and spindle speeds (1200, 2800, and 4400 rpm). Tool overhang lengths were selected as 10, 15, and 20 mm. During the experiments, the surface/burr shapes, cutting temperatures and cutting forces were observed. In general, it is observed that SiC filler reduces cutting forces and cutting temperatures. In the further stage of the study, Taguchi analysis was performed in the light of different SiC filler sizes, filler amounts, rotational speeds, and tool overhang lengths.
View
... The sheet thickness for these applications is typically s ! 100 µm. In the MASMICRO project, the feeding and processing of thinner sheet material with progressive dies has been investigated [Qin08]. Merklein et al. considered a concept for massive forming as linked parts. ...
Process Design
Chapter
Full-text available
  • Jan 2020
The design of micro production processes and systems faces a variety of significant challenges today. This is due both to economic and to technological challenges. Generally speaking, in most industries micro production tends to be characterized by mass production, meaning very high lot sizes from several thousands (e.g. in medical technology) to literally billions (e.g. resistor end caps in the electronics industry). Moreover, such micro parts are often produced under severe cost pressure, with the market price for an individual part often being only a fraction of a € cent.
View
... With regard to the tooling, the latest developments in forming processes have demonstrated that progressive die micro-forming is suitable to plastically deform ultra-thin sheets [17]. In successive stages, the metal strip is punched and bent successively to obtain the finished part. ...
Springback prediction for a mechanical micro connector using CPFEM based numerical simulations
Article
Full-text available
  • Jul 2020
The bending process of an industrial connector is considered and investigated via numerical simulation using a crystal plasticity finite element model (CPFEM). The process consists of sequentially bending a 0.1 mm thick copper-based alloy (CuBe2) with progressive tools into a miniature cylindrical connector of around 1 mm in diameter. The paper focuses on the prediction of springback through the influence of several key-parameters of the numerical simulations. The finite element characteristics, single crystal plasticity model features and the number of grains in the sheet thickness are investigated in order to highlight relevant and influential parameters in CPFEM based microforming process simulations. The influence of the elastic properties is analyzed and a modification of the Peirce-Asaro-Needleman single crystal hardening law is taken into account in order to improve the description of reverse strain path changes. Finally, the numerical results are discussed and compared to the springback measured during the industrial process of the cylindrical connector. It is demonstrated, through the very good agreement with the experimental results, that such approach can be useful to simulate industrial processes.
View
E-waste in Information and Communication Technology Sector: Existing scenario, management schemes and initiatives
Article
  • Jul 2022
The expeditious developments in technology along with the demand for a high-standard living have resulted in massive production of electronic gadgets, which eventually lead to the generation of huge quantities of obsolescence. With the exponential expanding output of computer hardware, efficient disposal of the electronic waste (E-waste) generated by the Information and Communication Technology (ICT) sector has become a serious concern. The ICT sector generates a major amount of E-waste, but its management strategies are not well defined. The present study explored the current status, challenges, and initiatives faced by the ICT sector in handling E-waste. Thereby, a framework of use case diagram has been put forth to develop a web-based model for recycling companies for solving E-waste recycling issues. This review also described the management strategies adopted by various ICT and electronic companies that have faced the challenge to mitigate the problems associated with E-waste.
View
Micro-machining of UHMWPE composites reinforced with carbide fillers
Article
Polymer matrix composites (PMCs) have become one of the most widely used engineering materials due to both the developments in polymers and advanced fillers. It is expected that polymer composites will take their final shape during the production phase, which means that they are not required to undergo new processes. However, in some applications, machining operations such as turning, milling, grooving and hole drilling cannot be avoided and thus, finishing operations must be applied to these materials. Since these materials have complex microstructures, finishing operations may cause situations that adversely affect engineering properties such as matrix cracking, delamination, debonding etc. In this study, micro-milling operations were performed for recently developed ceramic reinforced polymer composites. Three different spindle speeds were used while feed rate and cutting depth were kept constant in the operations. The composites were produced from powdered UHMWPE and silicon carbide particles. Several parameters were varied in the production of the composites such as molding pressure, filler loading and filler size. The investigated outputs were cutting temperature and surface roughness whereas machined surfaces and chip morphologies were also investigated via microscopy analyses. In the final stage, regression analyses were performed to investigate the relationships between the process parameters. According to the results, ceramic reinforced polymer composites exhibit different machinability properties than fiber reinforced ones due to hard fillers and low melting point of UHMWPE.
View
Challenge in magnesium microforming
Article
Full-text available
  • Feb 2021
Microforming is a method of manufacturing near-net shape micro parts by plastic deformation. This method has attracted much attention and is potentially adopted to manufacture various micro parts due to its distinct advantages, such as good strength of the deformed parts, high production rate, less scraps, and low cost. Among the materials studied in microforming research, copper is the most studied material, followed by aluminum and steel. Recently, magnesium has become an interesting research topic since the trend of magnesium application has emerged in electronics and medical fields. However, magnesium has low formability at room temperature that makes magnesium microforming a challenge. Hence, this paper discusses an overview about recent development in magnesium microforming and the challenges in controlling the size effect and formability of magnesium by elevated temperature and grain refinement.
View
Micromanufacturing of Composite Materials: A Review
Article
Full-text available
  • Mar 2019
Composite materials exhibit advantages from the combination of multiple properties, which cannot be achieved by a monolithic material. At present, the use of composite materials in miniaturized scale is receiving much attention in the fields of medicine, electronics, aerospace, and microtooling. A common method for producing miniaturized composite parts is micromanufacturing. There has been, however, no comprehensive literature published that reviews, compares, and discusses the ongoing micromanufacturing methods for producing miniaturized composite components. This study identifies the major micromanufacturing methods used with composite materials, categorizes their subclasses, and highlights the latest developments, new trends, and effects of key factors on the productivity, quality, and cost of manufacturing composite materials. A comparative study is presented that shows the potential and versatility associated with producing composite materials along with possible future applications. This review will be helpful in promoting micromanufacturing technology for fabricating miniaturized products made of composite materials to meet the growing industrial demand.
View
Grundlegende Untersuchungen zum Prozessverhalten von Silizium als Werkzeugwerkstoff für das Mikroscherschneiden metallischer Folien
Thesis
Full-text available
  • Jan 2017
Der Trend zur weiteren Miniaturisierung metallischer Bauteile stellt hohe Ansprüche an die Werkzeuge und deren Fertigung. Da etablierte Herstellmethoden hier an ihre technischen und wirtschaftlichen Grenzen stoßen, wird im Rahmen dieser Arbeit ein mikrosystemtechnischer Ansatz gewählt, bei dem Mikroschneidstempel mit Breiten unter 100 μm ätztechnisch gefertigt wurden. Auf Basis experimenteller und simulativer Untersuchungen werden die Grundlagen zum Einsatzverhalten von Siliziumwerkzeugen beim Mikroscherschneiden metallischer Folien erläutert.
View
Microforming
Article
Microforming is a well suited technology to manufacture very small metallic parts, in particular for mass production, as they are required in many industrial products resulting from microtechnology. Compared to other manufacturing technologies microforming features specific economical and ecological advantages. Nevertheless, there are only some singular applications known until today. This paper tries to find out the reason why, analyzing systematically the problems emerging in transferring the know-how on forming from the macro- to the microworld. Reviewing the state of the art in basic and applied research reveals that scaling effects do appear not only within the process but must be taken into account in all the other areas of the whole forming system as well, demanding finally new solutions especially for tool manufacturing and machine concepts. Recent progress, innovative ideas and new developments on these sectors represent a promising basis to exploit the inherent potential of microforming in the future.
View
Micro-forming and miniature manufacturing systems — development needs and perspectives
Article
As demands on miniature/micro-metal-products increase significantly, micro-metal-forming becomes an attractive option in the manufacture of these products due to its advantageous characteristics for mass production. Fundamental issues relating to materials, processes and analysis have been studied intensively in recent years and have been well documented in the literature. What are the challenges to further development that will be beyond “in-house” laboratory research? Machines, forming-tools and handling of micro-metal-parts are, for example, critical elements that significantly determine the industrial applications of micro-forming. Previous development was, however, diverse, and seemed lacking in systematic consideration. This keynote paper is dedicated to the exploration of the strategies concerning the development of equipment for micro-forming, through examining the state of the art of the development in this field and miniature manufacturing systems (micro-factory) as potential development models in particular, followed by introducing an EU fp6 Integrated Project in mass-manufacture of miniature/micro-products — MASMICRO project.
View
State of the art in micro forming and investigations into micro deep drawing
Article
Micro forming is an appropriate technology to manufacture very small metal parts, in particular for bulk production, as these are required in many industrial products resulting from microtechnology. This paper gives a review of the state-of-the-art in the micro forming of metals. The problems occurring in the miniaturisation of forming technologies such as micro massive forming and micro sheet metal forming are described. One of the problems is scaling effects, which e.g. occur in tribological aspects such as the friction coefficient, which increases with decreasing specimen size. Experimental investigations into micro deep drawing were carried out and the limit drawing ratio was determined. Furthermore, it was found that the friction coefficient in micro deep drawing at the flange and at the die radius are unequal and depend on the applied pressure.Scaling effects not only appear within the process but also must be taken into account in all other areas of the forming process chain, finally demanding new solutions, especially on tool manufacturing and machine concepts. The laser is an innovative tool, which can be used for rapid tooling, building up millimetre high free-standing structures, or for the generation of near net shape structures by laser erosion. The laser technique represents an auspicious tool for the tool manufacturing industry to exploit the inherent potential of micro forming in the future.
View
Advance in micro-manufacturing research and technological development and challenges/opportunities for micro-mecahnical machining’, Keynote paper, The Cutting Tool Congress
  • Y Qin
Microforming technology-on the way to industrial application”, Keynote paper
  • U Engel
Project Technical Reports
  • Consortium Eu Masmicro
State of the art in microforming and investigations into micro-deep drawing
  • F Vollerston
  • Z Hu
  • H Schulze Niehoff
  • C Theiler
Development of an integrated manufacturing facility for mass-manufacture of miniature/micro-products
  • Y Qin