Plastic anisotropy of ultra-thin rolled phosphor bronze foils and its thickness strain evolution in micro-deep drawing |
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| Affiliation: | 1. Division of Human Mechatronics Systems, Graduate School of System Design, Tokyo Metropolitan University, 6-6 Asahigaoka, Hino-shi, 191-0065 Tokyo, Japan;2. Department of Mechanical Engineering, Graduate School of Science and Engineering, Tokyo Metropolitan University, 1-1 Minamiohsawa, Hachioji-shi, 192-0397 Tokyo, Japan;1. School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore;2. Forming Technology Group, Singapore Institute of Manufacturing Technology, 71 Nanyang Drive, Singapore 638075, Singapore;1. National Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin 150001, China;2. School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, China;3. Key Laboratory of Micro-systems and Micro-structures Manufacturing (HIT), Ministry of Education, Harbin Institute of Technology, Harbin 150001, China |
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| Abstract: | Metal foils are highly advantageous for producing microcomponents with high-aspect-ratio three-dimensional shapes by miniaturizing the process dimensions in sheet-metal-forming technologies. To characterize existing rolled metal foils at manufacturing sites and to clarify the impact of its strong anisotropic properties on micro-sheet formability, tensile tests and micro-deep drawing tests were performed on phosphor bronze foils with thicknesses of 20–300 μm. Focusing on the Lankford value (r-value) as a useful parameter for conventional sheet-metal-formability, the relation between the r-value of ultra-thin rolled foil and its applicability in micro-deep drawing is investigated. Ultra-thin rolled foil is characterized with a higher r-value due to the strong texture of {1 1 0} and {1 1 1} textures. Although the in-plane tendency of the r-value showed a strong correlation with the thickness distribution of micro-drawn cups, the obtained higher r-value for thinner foils does not correspond to the lower formability of thinner metal foils. As relevant parameter for indicating the forming limit for thin-rolled metal foils, the nonuniformity in thickness due to surface roughening is introduced. The importance of a geometrical anisotropy, such as orientation of surface topography and defects, for the unstable deformation of ultra-thin rolled metal foils is experimentally demonstrated. |
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| Keywords: | Microforming Metal foils Plastic anisotropy Surface roughening Tensile test Micro-deep drawing |
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