NDLI: Fabrication and Investigation of a Micro-Progressive Die Set for Microforming of Sheet Metals

Content Provider	The American Society of Mechanical Engineers (ASME) Digital Collection
Author	Christopher, R. Nehme Sagar, Amrit William, C. Messner Thomas, P. James
Copyright Year	2014
Abstract	Progressive microforming is an attractive option for manufacturing high aspect-ratio micro-parts out of sheet metal. It is a highly economical alternative to both MEMS processing and micro-machining due to the ability to produce near-net shape parts through parallel forming processes. Current limitations in the field include precise alignment of microforming tools and an understanding of forces encountered when scaling down traditional forming processes. A five stage micro-progressive aluminum die set consisting of four shearing stages and one bending stage was fabricated by micro-machining. The die set was designed to produce right angle micro-brackets from 25 um thick annealed copper foil, with a measured average grain size of 47 um. Die clearances were set at 3 um along shearing edges and 38 um along the bending edge, corresponding to 12% and 152% material thickness, respectively. The produced micro-brackets are intended to be used as electrical connectors and consist of a nominally 280 um by 260 um tab extending vertically from a 780 um by 260 um base. In order to implement and investigate the progressive microforming process, a novel micro-press system was constructed which allows for precision alignment of the die set and workpiece. Using a prepared workpiece, forces at the first stage of the die set were measured and compared to analytical predictions based on models from the literature.
File Format	PDF
ISBN	9780791849590
DOI	10.1115/IMECE2014-36933
Volume Number	Volume 10: Micro- and Nano-Systems Engineering and Packaging
Conference Proceedings	ASME 2014 International Mechanical Engineering Congress and Exposition
Language	English
Publisher Date	2014-11-14
Publisher Place	Montreal, Quebec, Canada
Access Restriction	Subscribed
Subject Keyword	Grain size Microelectromechanical systems Copper foil Shearing (deformation) Aluminum Sheet metal Micromachining Manufacturing Shapes Die cutting
Content Type	Text
Resource Type	Article

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