Investigation on effect of ultrasonic vibration on micro-blanking process of copper foil

Investigations have revealed that size effect obviously affects forming quality and accuracy of micro parts. However, to find effective approaches that can reduce the influence of size effect is still a critical problem to be solved. Ultrasonic vibration has been widely used in industrial metal form...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2017-11, Vol.93 (5-8), p.2243-2249
Main Authors: Liu, Yang, Wang, Chunju, Han, Haibo, Shan, Debin, Guo, Bin
Format: Article
Language:English
Subjects:
Blanking
CAE) and Design
Computer-Aided Engineering (CAD
Copper
Crack initiation
Deformation
Deformation mechanisms
Engineering
Fillets
Forming
Industrial and Production Engineering
Machine tool industry
Mechanical Engineering
Media Management
Metal foils
Metal forming
Microelectromechanical systems
Microstructure
Original Article
Quality
Shearing
Size effects
Surface properties
Surface roughness
Ultrasonic vibration
Vibration analysis
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Summary:Investigations have revealed that size effect obviously affects forming quality and accuracy of micro parts. However, to find effective approaches that can reduce the influence of size effect is still a critical problem to be solved. Ultrasonic vibration has been widely used in industrial metal forming recently, and it has been proved that it is helpful for improving section quality compared with conventional blanking. In this study, micro-blanking process was carried out with a specially developed device. The square holes of copper foil T2 were investigated by analyzing the evolution of microstructure, crack initiation, quality of shearing surface, etc. Inhibition of crack initiation is found due to the softening effect in ultrasonic vibration assisted micro-blanking by analyzing section obtained under different ratios of blanking stroke to thickness ( h/t ), which increases the ratio of smooth zone. The analysis of microstructure in deformation area shows that a shearing deformation area becomes smaller, and radius of fillet decreases. Surface roughness of smooth zone decreases with ultrasonic vibration due to polishing effect. Compared with traditional micro-blanking, this compound plastic forming technology applying ultrasonic vibration on the punch can improve the section surface quality by increasing the ratio of smooth zone, and decreasing the surface roughness and fillet radius. The experimental outcomes reveal the mechanism of shearing deformation behavior during ultrasonic vibration assisted micro-blanking process of copper foil and the findings confirm that ultrasonic vibration can be regarded as a way to improve the forming quality of micro-blanking.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-017-0684-4