Fundamentals of Modern Manufacturing: Materials, Processes and Systems

Size effects in manufacturing of metallic components

Advanced Issues in springback

Considerable changes have occurred in metal forming in the last decade. A record of these changes can be found in keynote papers presented by the members of the Scientific Technical Committee—Forming, at the CIRP Annual General Meeting each year. The keynote papers are excellent references on important developments in metal forming and are used as a reference, globally. Not only is this paper a compendium of most of the keynotes presented, but from 2001 onward, it has updates on new information on five keynote subject areas. The authors of each keynote have written an update with new information that has developed since the writing of the keynote. The authors of each section are shown in order of presentation.

Metal forming progress since 2000

Product miniaturization is an emerging trend for facilitating product usage, enabling unique product functions to be implemented in micro-scaled geometries and features, and further reducing product weight and volume. Recently, a demand for microparts increased significantly in many industry clusters. Development of the advanced micromanufacturing technologies for fabrication of such microparts has thus become a critical issue. Microforming, which offers attractive characteristics including high productivity, low cost and good quality of the formed parts, provides a promising approach to fabricating metallic microparts. In the last two decades, a lot of effort has been made to the researches on size effect related deformation behaviors in microforming process and the development of the process. Having a panorama of these researches is necessary to support micropart design and development via microforming, and further advance this micromanufacturing process. In this paper, an intensive review on the latest development of microforming technologies is presented. First of all, the paper is focused on the review of the size effect-affected deformation behaviors and the mechanisms of the changes of flow stress, flow behavior, fracture behavior, elastic recovery, tooling–workpiece interfacial friction and the surface finish of the formed parts. The state-of-the-art microforming processes, including micro deep drawing, microembossing, micropunching, microcoining, microextrusion, microheading, and micro progressive forming are then presented. Finally, some research issues from the implementation of mass production perspective are also discussed.

A review on the state-of-the-art microforming technologies

An experimental study on size effects on flow stress and formability of aluminm and brass for microforming

A new model for springback prediction in which the Bauschinger effect is considered

Springback behavior of brass in micro sheet forming

An experimental investigation of the influence of the Bauschinger effect on springback predictions

Springback control of sheet metal air bending process

Jenn Terng Gau

Papers

An experimental study on size effects on flow stress and formability of aluminm and brass for microforming

A new model for springback prediction in which the Bauschinger effect is considered

Springback behavior of brass in micro sheet forming

An experimental investigation of the influence of the Bauschinger effect on springback predictions

Springback control of sheet metal air bending process