Abstract
Flange forming is a process which is wide spread in macro range for blanks with thicknesses from less than 1 mm up to several millimeters. Flange formed geometries are used as preforms for threads but also as device to give guidance and contact face to bolts and axles in sheet metal. A great advantage of flange forming compared to other machining processes is low process cycle time combined with high material utilization. Thus, a reasonable repertoire of knowledge has been gained for flange forming in macro range. Due to ongoing miniaturization of today’s products, flange forming is an interesting process applicable in micro range as well whereas size effects do not generally allow transfer of process limits from macro to micro range. Therefore the maximum flaring ratio for flange forming in micro range for sheet metal foil of 10–25 μm for a stainless steel 1.4301 and Copper E-Cu58 is investigated and compared with results in macro range. It is shown that the maximum flaring ratio decreases with decreasing sheet metal thickness. The resulting flange heights of experiments are compared with theoretical estimations which show a good accordance.
Similar content being viewed by others
References
Sanders R (2003) Physicists build world’s smallest motor using nanotubes and etched silicon. http://berkeley.edu/news/media/releases/2003/07/23_motor.shtml. Accessed 15 May 2012
da Silva AK, Kobayashi MH, Coimbra CFM (2006) Optimal design of non-newtonian micro-scale viscous pumps for biomedical devices. Wiley Inter Sci. doi:10.1002/bit.21165
Masuzawa T (2000) State of the art of micromachining. Ann CIRP 49:473–488
Vollertsen F, Hu Z (2007) On the drawing limit in micro deep drawing. J Technol Plast 32(1/2):1–11
Vollertsen F, Walther R (2008) Energy balance in laser-based free form heading. Ann CIRP 57:291–294
Vollertsen F (2011) Size effects in micro forming. 14th International Conference on Sheet Metal (Sheet Metal 2011), eds.: Duflou J.R, Clarke R, Merklein M, Micari F, Shirvani B, Kellens K. Trans Tech Publications Zürich-Durnten, pp 3–12
Hu Z, Vollertsen F (2009) Größenabhängige FEM-Simulation für die Blechumformung. In: Vollertsen F (ed) Größeneinflüsse bei Fertigungsprozessen. Abschlusskolloquium Prozessskalierung, BIAS-Verlag, pp 57–78
Yamaguchi K, Sagrado R, Takakura N, Lizuka T (2002) Effect of thickness on the restoration behavior of sheet metals subjected to bulge deformation, ICTP. Int Conf Technol Plast 7:997–1002
Tracht K, Weikert F, Hanke T, Kuhfuß B, Hellwig C (2011) Modeling of linked parts in micro-forming transformation of product-defining data into a product model for ladder type linked parts. wt Werkstattstechnik online 101 pp 765–769
Spur G, Stöferle T (1985) Handbuch der Fertigungstechnik – Umformen, Zerteilen. Band 2. Carl Hanser Verlag. München, Wien
Wilken R (1957) Das Biegen von Innenborden mit Stempeln. Technical University of Hannover, Dissertation
Vollertsen F (2008) Categories of size effects. Prod Eng Res Develop 2(4):377–383
Hu Z, Vollertsen F (2010) Effect of size and velocity dependent friction in deep drawing on the process window. 4th International Conference on Tribology in Manufacturing Processes (ICTMP2010), eds.: Felder E, Montmitonnet P. Transvalor Paris pp 583–592
Schlagau S (1988) Verfahrensverbesserung beim Kragenziehen durch Überlagerung von Druckspannungen. Dissertation, TH Darmstadt
Klocke F, König W (2006) Fertigungsverfahren—Umformen. Springer-Verlag, Berlin
Erhardt R (2004) Laserunterstütztes Umformen miniaturisierter Bauteile am Beispiel des Tief- und Kragenziehen. Technical University of Darmstadt, Dissertation
Lange K (1990) Umformtechnik, Handbuch für Industrie und Wissenschaft Band 3. Springer-Verlag, Berlin
Acknowledgments
The authors gratefully acknowledge the financial support by Deutsche Forschungsgesellschaft (DFG, German Research Foundation) for Subprojekt A3 “Stoffanhäufen” within the SFB 747 (Collaborative Research Centre) “Mikrokaltumformen—Prozesse, Charakterisierung, Optimierung”.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Brüning, H., Vollertsen, F. Mechanical flange forming in steel and copper foil. Prod. Eng. Res. Devel. 6, 551–558 (2012). https://doi.org/10.1007/s11740-012-0412-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11740-012-0412-8