TY - JOUR
T1 - Study on size-related product quality of multiscale central-punched cups fabricated by compound forming directly using brass sheet
AU - Hu, Dien
AU - Zheng, Jun Yuan
AU - Fu, Mingwang
N1 - Funding Information:
The authors would like to acknowledge the funding support to this research from the NSFC key project of No. 51835011 of the National Natural Science Foundation of China, the project of ZE1W from The Hong Kong Polytechnic University, and the project of 15223520 from the General Research Fund of Hong Kong Government.
Publisher Copyright:
© 2022, The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature.
PY - 2022/6
Y1 - 2022/6
N2 - Meso/microforming has gained much more attention in the last decades and is widely used as a reliable method to fabricate meso/micro-scaled metallic components. In this research, a compound meso/microforming system which combines deep drawing, punching, and blanking operations was developed to fabricate multiscale central-punched cups by using brass sheets. The parts with three scales were produced by using the brass sheets with various thicknesses and grain sizes to investigate geometrical and grain size effects on the deformation behaviors, dimensional accuracy, and material flow behaviors in the forming process. Through physical experiments and finite element simulations, it is revealed that the ultimate deformation load in the drawing-punching stage is smaller than that in the single deep drawing stage under microscale, but the results in the meso-scaled scenarios are opposite. In addition, the thickness variation is increased with grain size, but the variation of the normalized thickness variation does not show an obvious tendency with different size scales. In the bending area, the material flow is tangential to the thickness direction, leading to the formation of thinning area. In addition, the material flow is almost opposite to the punching direction in the punching area, avoiding the expanding deformation of the hole. Thus, the punching operation barely affects the dimensional accuracy including the thickness and hole diameter of the formed parts. Furthermore, the micro-scaled cups with finer grains have a better surface quality. These findings enhance the understanding of size effect in compound meso/microforming with the combined deep drawing and punching operations.
AB - Meso/microforming has gained much more attention in the last decades and is widely used as a reliable method to fabricate meso/micro-scaled metallic components. In this research, a compound meso/microforming system which combines deep drawing, punching, and blanking operations was developed to fabricate multiscale central-punched cups by using brass sheets. The parts with three scales were produced by using the brass sheets with various thicknesses and grain sizes to investigate geometrical and grain size effects on the deformation behaviors, dimensional accuracy, and material flow behaviors in the forming process. Through physical experiments and finite element simulations, it is revealed that the ultimate deformation load in the drawing-punching stage is smaller than that in the single deep drawing stage under microscale, but the results in the meso-scaled scenarios are opposite. In addition, the thickness variation is increased with grain size, but the variation of the normalized thickness variation does not show an obvious tendency with different size scales. In the bending area, the material flow is tangential to the thickness direction, leading to the formation of thinning area. In addition, the material flow is almost opposite to the punching direction in the punching area, avoiding the expanding deformation of the hole. Thus, the punching operation barely affects the dimensional accuracy including the thickness and hole diameter of the formed parts. Furthermore, the micro-scaled cups with finer grains have a better surface quality. These findings enhance the understanding of size effect in compound meso/microforming with the combined deep drawing and punching operations.
KW - Compound forming
KW - Deformation behaviors
KW - Dimensional accuracy
KW - Meso/microformed parts
KW - Size effect
KW - Surface quality
UR - http://www.scopus.com/inward/record.url?scp=85128709590&partnerID=8YFLogxK
U2 - 10.1007/s00170-022-09222-z
DO - 10.1007/s00170-022-09222-z
M3 - Journal article
AN - SCOPUS:85128709590
SN - 0268-3768
VL - 120
SP - 7235
EP - 7249
JO - International Journal of Advanced Manufacturing Technology
JF - International Journal of Advanced Manufacturing Technology
IS - 11-12
ER -