• Transactions of Materials Processing
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• v.14 no.5 s.77
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• pp.432-438
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• 2005

Among the most of manufacturing process, plastic deformation method offers a significant advantage in productivity and enable mass production with controlled quality and low cost. From the point of view, micro forming is a well suited technology in manufacturing very small metallic parts, in particular for mass production, as they are required in many industrial products. Meanwhile, Al 5083 superplastic alloy with very small grains has a great advantage in achieving micro deformation under low stress due to its relatively low strength at a specific high temperature range. This paper describes the micro formability of Al 5083 superplastic alloy and its application to die forging of micro patterns. Micro formability tests of Al 5083 superplastic alloy were carried out with the specially designed micro forging system by using V-grooved micro dies and pyramidal dies made of (100) silicon. With these dies, micro forging was conducted by varying the applied load, material temperature and forging time The micro formability of Al 5083 superplastic alloy was evaluated by comparing $R_f$ value, where $R_f\;=\;A_f/A_v$ ($A_v$ : cross-sectional area of the flowed metal, $A_v$ : cross sectional area of V-groove). The micro formability of 3 dimensional Patterns was also evaluated using Pyramidal type micro dies.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.4 s.181
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• pp.153-161
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• 2006

Micro-forming is a suited technology to manufacture very small metallic parts(several $mm{\sim}{\mu}m$). Micro-forming of $Zr_{62}Cu_{17}Ni_{13}Al_8$ bulk metallic glass(BMG) as a candidate material for this developing process are feasible at a relatively low stress in the supercooled liquid state without any crystallization during hot deformation. In this study, micro- formability of a representative bulk metallic glass, $Zr_{62}Cu_{17}Ni_{13}Al_8$. was investigated for micro-forging of U-shape pattern. Micro-formability was estimated by comparing $R_f$ values ($=A_f/A_g$), where $A_g$ is cross-sectional area of U groove, and $A_f$ the filled area by material. Micro-forging process was simulated and analyzed by applying finite element method. FEM simulation results showed reasonable agreement with the experimental results when the material properties and simulation conditions such as top die speed, remeshing criteria and boundary conditions were tightly controlled. The micro-formability of $Zr_{62}Cu_{17}Ni_{13}Al_8$ was increased with increasing load and time in the temperature range of the supercooled liquid state. Also, FEM simulation using a commercial software, DEFORM was confirmed to be applicable for the optimization of micro-forming process.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.6
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• pp.193-200
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• 2007

Micro forming is a suited technology to manufacture very small metallic parts(several $mm{\sim}{\mu}m$). Al5083 superplastic alloy with very small grains has a great advantage in achieving micro deformation under low stress due to its relatively low strength at a specific high temperature range. Micro forming of $Zr_{62}Cu_{17}Ni_{13}Al_8$ bulk Metallic glass(BMG) as a candidate material for this developing process are feasible at a relatively low stress in the supercooled liquid state without any crystallization during hot deformation. In this study, the micro formability of Al5083 superplastic alloy and bulk metallic glass, $Zr_{62}Cu_{17}Ni_{13}Al_8$, was investigated with the specially designed micro vibration forming system using pyramid-shape, V-shape and U-shape micro die pattern. With these dies, micro vibration forming was conducted by varying the applied load, time. Micro formability was estimated by comparing the hight of formed shape using non-contact surface profiler system. The vibration load effect to metal flow in the micro die and improve the micro formability of Al5083 superplastic alloy and $Zr_{62}Cu_{17}Ni_{13}Al_8$ bulk Metallic glass(BMG).

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.589-592
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• 2005

Micro-forming is a suited technology to manufacture very small metallic parts(several $mm{\sim}{\mu}m$). Micro-forming of $Zr_{62}Cu_{17}Ni_{13}Al_8$ bulk metallic glass(BMG) as a candidate material for this developing process are feasible at a relatively low stress in the supercooled liquid state without any crystallization during hot deformation. In this study, micro-formability of a representative bulk metallic glass, $Zr_{62}Cu_{17}Ni_{13}Al_8$, was investigated for micro-forging of U-shape pattern. Micro-formability was estimated by comparing $R_f$ values $(=A_f/A_g)$, where Ag is cross-sectional area of U groove, and $A_f$ the filled area by material. Microforging process was simulated and analyzed by applying finite element method. FEM simulation results should reasonable agreement with the experimental results when the material properties and simulation conditions such as top die speed, remeshing criteria and boundary conditions tightly controlled. The micro-formability of $Zr_{62}Cu_{17}Ni_{13}Al_8$ was increased with increasing load and time in the temperature range of the supercooled liquid state. Also, FEM Simulation using DEFORM was confirmed to be applicable for the micro-forming process simulation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.09a
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• pp.49-53
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• 2005

The objective of this research was to establish the size limitation of micro metal forming and analyze the formability of foil. Flat-rolled ultra thin metallic copper foil($3{\mu}m$ in thickness) was used as a forming material and foil was annealed to improve the formability at the temperature of $385^{\circ}C$. Forming die was fabricated by using etching technique of DRIE(deep reactive ion etching) and HNA isotropic etching. For the forming die and coupe. foil were vacuum packed and the forming was conducted as applying hydrostatic pressure of 250MPa to the vacuum packed unit. We successfully obtained the micro channels of $12\~14{\mu}m$ width and $9{\mu}m$ depth from micro forming process we designed. We also investigated the thickness strain distribution of foil from experiment and FE simulation result. Micro channels had a good formability of smooth surface and size accuracy. We expect that micro metal forming technology will be applied to production of micro parts.

• Transactions of Materials Processing
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• v.7 no.4
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• pp.400-406
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• 1998

The press formability analysis of welding parts was studied in the current work by the tailor welded blank. The press formability was tested by means of the flash weldability and the formability for two kinds of materials (SPCC & S35C). The results indicate that SPCC & S35C steel sheets showed good weldability and formability after an optimum welding conditions. The independent operation variables were characterized by strength of welding parts, deformation after the welding, press formability of welding parts and productibility of welding. The weldability and the quality of welding parts of the flashed SPCC steel sheet was superior to those of the S35C steel sheet, since a higher carbon content in steel sheet led to a higher hardness. The experimental results were discussed by the evaluation of the results obtained from tensile test, hardness test, micro-structure and V bending test.

• Transactions of Materials Processing
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• v.19 no.6
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• pp.352-356
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• 2010

This paper was designed to fabricate the micro-spur gear by the LIGA and hybrid powder extrusion process. It is important to manufacture a micro-die with a high aspect ratio and determine appropriate extrusion conditions for a microforming. Ni has been used to fabricate micro-dies. LIGA process was capable to produce micro-extrusion dies with close tolerance, longer bearing length and adequate surface quality. Superplastic Al-78Zn powders have the great advantage in achieving deformation under low stresses and exhibiting good micro-formability with average strain rate raging from $10^{-3}$ to $10^{-2} s^{-1}$ and constant temperature ranging from 503 to 563K. Al-78Zn powders were compacted into a cylindrical shape ($\Phi3\times$h10mm) under compressive force of 10kN and, subsequently, the compacted powders were extruded by the hybrid powder extrusion process controlling of the temperature holing time for a improvement on formability of Al-22Zn powder. Micro-extrusion has succeeded in forming micro-gear shafts.

• Korean Journal of Metals and Materials
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• v.49 no.2
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• pp.104-111
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• 2011

An ultrafine grained Mg-9Al-1Zn magnesium alloy with the mean grain size less than $1{\mu}m$ was produced by using high-ratio differential speed rolling. The processed alloy exhibited excellent superplasticity at relatively low temperatures. The micro-forming tests were carried out using a micro-forging apparatus with micro V-grooved shaped dies made of silicon and the micro-formability was evaluated by means of micro-formability index, $R_f$ ($=A_f/A_g$, $A_f$: formed and inflowed area into the V-groove, $A_g$: area of the V-groove). The $R_f$ value increased with temperature up to $280^{\circ}C$ and then decreased beyond $300^{\circ}C$. The decrease of the $R_f$ value at $300^{\circ}C$ was attributed to the accelerated grain coarsening. Increasing the micro-forging pressure increased the $R_f$ values. At a given die geometry, die filling ability decreased as the die position moved away from the die center to the end. FEM simulation predicted this behavior and a method of improving this problem was proposed.

• Transactions of Materials Processing
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• v.15 no.4 s.85
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• pp.304-310
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• 2006

Due to a recent growth of the area of MEMS and a trend moving toward smaller scale, a micro manufacturing that is usually related with lithography is now emerging. Differently from traditional manufacturing processes, the micro or miniature manufacturing usually requires expensive sophisticated equipments and its characteristics are of high cost and of low productivity. However, a miniature stamping, which makes small sized product with a thin metal usually in the range of meso-scale, can be realized in a low cost and in a high productivity with relatively inexpensive equipments. For a successful development of miniature stamping, lots of obstacles, including material properties related with formability, have to be overcome. Since the thin metal shows distinctive characteristics, e.g., size effect and statistically scattered material properties, the formability of miniature stamping is not good in general and the possible shape with the miniature stamping is limited relatively simple shapes. Since the optimal blank improves formability and the improved formability can make up for problems of material properties, the possibility of success can be increased. This study is carried out to show the possibility of miniature stamping and to verify the effect of optimal blank for the miniature stamping.

• Transactions of Materials Processing
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• v.8 no.1
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• pp.57-64
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• 1999

The press formability analysis of welding parts was studied in the current work by the tailor welded blank. As the body panel is used in the press forming of welding parts by a weld method of the tailor welded blank, the following conditions are demanded: 1) The strength of welding parts must be the higher than base metals. 2) After the welding, severe welding deformatins must be avoided. 3) The press formability of welding parts is similar to that of many base metals. 4) The productibility of a welding has to be higher. There are many welding methods satisfying these conditions, but the purpose of this study is to inbestigate the upset weldability and formability of the material (SPCC). SPCC steel sheet showed good weldability and formability under some welding conditions. The experimental results were discussed by the evaluation of the results obtained from tensile tests, hardness tests, micro-structures and Erichsen cup test was a little lower than that of parent material.