from the conferences organized by TANGER Ltd.
Micro-forming is one of the most popular micro manufacturing processes for manufacturing vsmall metallic parts in sub millimetre range. The proposed process is called Micro-Blanking with Mutual Calibration - MBMC. It involves performing micro-blanking and then pushing the disk back through the resulting hole using a counter-punch. The product shape is corrected and the burr is eliminated. It is possible with proper selection of slack. A method has been proposed to determine the appropriate clearance value based on the results of FEM modeling assessed using the proposed parameters. FEM models are created based on the analysis of the results of only one specially designed MBMC process replacing a number of costly experiments. It is a process in which, with a nominal clearance of 5%, the punch axis is shifted in relation to the matrix axis by about 1/3 of the clearance. This results in a smoothly changing clearance in the range of 1.5 - 8.5%. Modeling parameters are adjusted to the separation surface shapes and burr occurrence obtained for individual clearances. The case of the MBMC process concerning a disk punched with a punch of 1 mm in diameter out of 0.25 mm thick CuZn37 brass in hardened condition was analyzed. A method of assessing the broadly understood quality of a punched micro-product was proposed, based on the analysis of the geometry of the cross-sectional outline of the punched disc and hole. Using this method, it was shown that the MBMC process increases the quality of the product in relation to the blanking alone in the range of 0.7 to 2.2% of clearance.
Keywords: Microforming, micro-blanking, burr-less blanking© This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.