Sheet metal meso- and microforming and their industrial applications

317 Pages·2019·26.79 MB·English

by  Fu, Ming Wang, Lai, Xin Min, Peng, Lin Fa

Sheet Metal Meso- and
Microforming and Their
Industrial Applications

Sheet Metal Meso- and
Microforming and Their
Industrial Applications
Xin Min Lai, Ming Wang Fu, and
Lin Fa Peng
CRC Press
Taylor & Francis Group
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Library of Congress Cataloging‑in‑Publication Data
Names: Lai, Xin Min, author. | Fu, Ming Wang, author. | Peng, Lin Fa, author.
Title: Sheet metal meso- and microforming and their industrial applications/Xin
Min Lai, Ming Wang Fu, Lin Fa Peng.
Description: First edition. | Boca Raton, FL : CRC Press/Taylor & Francis Group,
2019. | “A CRC title, part of the Taylor & Francis imprint, a member of the
Taylor & Francis Group, the academic division of T&F Informa plc.” | Includes
bibliographical references and index.
Identifiers: LCCN 2018014812| ISBN 9781138033160 (hardback : acid-free paper) |
ISBN 9781138033177 (ebook)
Subjects: LCSH: Micromachining. | Sheet-metal work.
Classification: LCC TJ1191.5 .L35 2019 | DDC 671.3/5--dc23
LC record available at https://lccn.loc.gov/2018014812
Visit the Taylor & Francis Web site at
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Contents
Preface ......................................................................................................................xi
Acknowledgments ................................................................................................xv
Authors ................................................................................................................xvii
1. Introduction .....................................................................................................1
1.1 Introduction ...........................................................................................1
1.2 Meso- and Microscaled Bulk Metal Forming ...................................3
1.3 Meso- and Microscaled Sheet Metal Forming ..................................5
1.4 Summary ................................................................................................6
References .........................................................................................................7
2. Size Effects in Meso- and Microscaled Forming .....................................9
2.1 Introduction ...........................................................................................9
2.2 Scaling Law in Multiscaled Forming Processes .............................10
2.3 Size Effect Affected Material Behaviors ..........................................11
2.4 Flow Stress Modeling in Meso- and Microforming .......................14
2.4.1 Surface Layer Model ..............................................................16
2.4.1.1 Modeling .................................................................17
2.4.1.2 Verification ..............................................................20
2.4.2 Grain Boundary Model .........................................................23
2.4.2.1 Modeling .................................................................24
2.4.2.2 Verification ..............................................................26
2.4.3 Crystal Plastic Model ............................................................27
2.4.4 Modified Hall–Petch Model .................................................30
2.5 Grain Statistics and Orientation Effect ............................................31
2.5.1 Surface Roughening and Scattering ....................................31
2.5.2 Constitutive Model with Orientation Effect ......................34
2.5.3 Simulation with Consideration of Grain Statistics ............38
2.6 Strain Gradient Plasticity Model .......................................................42
2.6.1 Taylor Dislocation Model ......................................................42
2.6.2 Constitutive Model of CMSG ...............................................44
2.6.3 Simulation of Microdeformation Based on CMSG
Model .......................................................................................44
2.7 Summary ..................................................................................................47
References .......................................................................................................48
3. Friction in Meso- and Microforming of Materials ................................53
3.1 Introduction .........................................................................................53
3.2 Size Effects on Interfacial Friction ....................................................54
3.2.1 Experimental Observation of Geometry Size Effect .........55
v
vi Contents
3.2.1.1 Ring Compression ..................................................55
3.2.1.2 Double-Cup Extrusion ...........................................57
3.2.1.3 Cylinder Compression ...........................................58
3.2.2 Experimental Observations of Grain Size Effect ...............61
3.2.2.1 Kolsky Bar Friction Test.........................................61
3.2.2.2 Block-on-Ring Friction Test ...................................62
3.2.2.3 Pin-on-Disk Friction Test.......................................64
3.3 Modeling and Analysis of Friction Behavior ..................................70
3.3.1 Grain Size Affected Adhesive Friction Behavior ..............70
3.3.1.1 Asperity Contact Model ........................................72
3.3.1.2 Modified Sphere-Flat Contact Model
Considering Material Hardening Effect .............74
3.3.1.3 Interfacial Friction Stress and Junction
Growth ..................................................................76
3.3.1.4 Asperity Friction Model ........................................77
3.3.1.5 Grain Size Effects ...................................................79
3.3.2 Grain Size Affected Plowing Friction Behavior ................82
3.3.2.1 Plowing Model Considering Elastic Recovery ....82
3.3.2.2 Plowing Friction Behaviors Considering
Fracture Behaviors .................................................83
3.3.2.3 Comparison of the Models ....................................86
3.3.3 Geometry Size and Surface Asperity Affected
Friction Behavior ....................................................................88
3.3.3.1 O/CLP Model ..........................................................88
3.3.3.2 Friction Model in Meso- and Microscaled
Plastic Deformation ................................................90
3.3.3.3 FE Simulation of Friction Behaviors in
Meso- and Microforming ......................................93
3.3.3.4 Analysis and Discussion .......................................96
3.4 Summary ..............................................................................................98
References .......................................................................................................99
4. Instability and Formability of Materials in Meso- and
Microforming ..............................................................................................103
4.1 Introduction .......................................................................................103
4.2 Forming Limit Measurement by Experiments .............................105
4.2.1 Material Characterization ...................................................105
4.2.2 Forming Limit Experiments ...............................................109
4.2.2.1 Experiment Design ..............................................111
4.2.2.2 Strain Measurement .............................................112
4.2.2.3 Limit Strain Determination ................................115
4.2.3 Results and Discussion .......................................................116
4.2.3.1 Deformation Process ............................................117
4.2.3.2 FLD and FFLD Results ........................................118
4.2.3.3 Load Path ...............................................................121
Contents vii
4.2.3.4 Microstructure Observation ...............................123
4.2.4 S ummary of Experimental Investigation .........................126
4.3 Prediction of Size Effect Affected FLC Based on Theoretical
Models ................................................................................................126
4.3.1 S wift Diffuse and Hill-Localized Criteria ........................127
4.3.2 M arciniak–Kuczynski Model .............................................130
4.3.3 U ncoupled DF Criteria ........................................................134
4.3.3.1 Freudenthal Criterion ..........................................134
4.3.3.2 Ayada Criterion ....................................................135
4.3.3.3 Cockcroft & Latham Criterion ............................135
4.3.3.4 Oyane Criterion ....................................................136
4.3.4 GTN–Thomason Model .......................................................138
4.3.5 Summary of the Theoretical Discussion ..........................144
4.4 Modeling of Size Effect Based on the GTN–Thomason
Model.............................................................................................148
4.4.1 Modeling Process Considering Size Effect ......................148
4.4.1.1 Void Nucleation ....................................................148
4.4.1.2 Void Growth ..........................................................150
4.4.1.3 Void Coalescence ..................................................151
4.4.2 FE Simulation and Discussion ...........................................154
4.4.2.1 Parameter Discussion ..........................................154
4.4.2.2 Parameter Determination ...................................157
4.4.2.3 FLC Construction and Discussion .....................160
4.5 Simulation and Validation ...............................................................164
4.6 Summary ............................................................................................169
References .....................................................................................................170
5. Meso- and Microforming of Sheet Metals for Making Sheet
Metal Parts and Components ...................................................................175
5.1 Introduction .......................................................................................175
5.2 Microsheet Bending Process ...........................................................176
5.2.1 Loading and Displacement in Microbending Process ......176
5.2.2 Springback Angle Analysis ................................................178
5.2.2.1 Effect of Specimen Thickness .............................179
5.2.2.2 Effect of Grain Size ...............................................181
5.2.2.3 Effect of Deformation Angle ...............................181
5.2.2.4 Effect of t/d ............................................................181
5.3 Micro Deep Drawing Process .........................................................185
5.3.1 Deformation Behavior .........................................................185
5.3.2 Thickness Variation .............................................................188
5.4 Microsheet Metal Hydroforming ...................................................190
5.4.1 Processing Procedure ..........................................................191
5.4.2 Analysis of Deformation .....................................................194
5.5 Microflexible Forming of Sheet Metals by Soft Punch ................198
5.5.1 Interface Friction ..................................................................198
viii Contents
5.5.2 Hardness of Soft Punch ......................................................200
5.5.3 Grain Size Effect ...................................................................202
5.6 Summary ............................................................................................204
References .....................................................................................................205
6. Meso- and Microscaled Sheet-Metal Parts Made by Meso- and
Microstamping Processes .........................................................................209
6.1 Introduction .......................................................................................209
6.2 Meso- and Microsheet Metal Products Made by Stamping
Processes ............................................................................................212
6.2.1 Microreactor..........................................................................212
6.2.2 Micro Heat Exchanger .........................................................215
6.2.3 Micromixer ...........................................................................217
6.3 Process Realization: A Case Study .................................................218
6.3.1 Process Realization and the Issues Involved in
Fabrication of BPPs ..............................................................218
6.3.2 Meso- and Microstamping with Rigid Punch .................221
6.3.2.1 Rigid Tooling Stamping ......................................221
6.3.2.2 Design of BPP Flow Channels ............................226
6.3.2.3 Tooling Fabrication and BPP Manufacturing .....231
6.3.3 Meso- and Microstamping with Soft Punch ....................234
6.3.3.1 Flow Channel Design for Manufacturability ....235
6.3.3.2 Formability of BPPs by Soft Punch Stamping ....239
6.3.3.3 BPP Manufacturing and Analysis .....................239
6.4 Summary ............................................................................................242
References .....................................................................................................242
7. Meso- and Microscaled Bulk Components Produced by
Progressive and Compound Forming of Sheet Metals .......................247
7.1 Introduction .......................................................................................247
7.2 Progressive and Compound Bulk Forming of Sheet Metals ......250
7.2.1 Meso- and Microscaled Bulk Components ......................250
7.2.2 Progressive and Compound Meso- and
Microforming System ..........................................................251
7.3 Shearing Deformation in the Process.............................................255
7.3.1 Shearing Deformation .........................................................255
7.3.2 Deformation Load ................................................................257
7.3.3 Working Hardening Induced by Shearing.......................261
7.3.4 Dimensional Accuracy ........................................................263
7.3.5 Speed Affected Deformation Behavior and Part
Quality ...................................................................................269
7.4 Progressive and Compound Deformation in the Process ...........273
7.4.1 Deformation Behavior .........................................................273
7.4.1.1 Deformation Load ................................................273
7.4.1.2 Material Flow Behavior .......................................274
Contents ix
7.4.2 Ductile Fracture Behavior ...................................................276
7.4.2.1 Fracture Surface ....................................................276
7.4.2.2 Analysis of Ductile Fracture ...............................279
7.4.3 Dimensional Accuracy of Deformed Parts ......................286
7.4.3.1 Undesired Progressive Deformation .................286
7.4.3.2 Dimensional Accuracy ........................................287
7.5 Summary ............................................................................................289
References .....................................................................................................289
Index .....................................................................................................................291