Cold Micro Metal Forming : : Research Report of the Collaborative Research Center Micro Cold Forming (SFB 747), Bremen, Germany.

• Superior document: Lecture Notes in Production Engineering Series
• Author: Vollertsen, Frank.
• TeilnehmendeR: Friedrich, Sybille.; Kuhfuß, Bernd.; Maaß, Peter.; Thomy, Claus.; Zoch, Hans-Werner.
• Place / Publishing House: Cham : : Springer International Publishing AG,, 2019.; ©2020.
• Year of Publication: 2019
• Edition: 1st ed.
• Language: English
• Series: Lecture Notes in Production Engineering Series
• Physical Description: 1 online resource (370 pages)

Table of Contents

• Intro
• Preface
• Contents
• Contributors
• 1 Introduction to Collaborative Research Center Micro Cold Forming (SFB 747)
• 1.1 Motivation
• 1.2 Aim of the SFB 747
• 1.3 Structure and Partners
• 1.4 Main Results
• 1.4.1 Innovation Speed
• 1.4.1.1 Process Design
• 1.4.1.2 Design of Production Systems
• 1.4.2 Micro Mass Forming
• 1.4.2.1 Tribology
• 1.4.2.2 Scatter
• 1.4.3 Mastered Production
• 1.4.3.1 Measurement and Quality Control
• 1.4.3.2 Handling
• 1.4.3.3 Thermal Aspects
• References
• 2 Micro Forming Processes
• 2.1 Introduction to Micro Forming Processes
• 2.2 Generation of Functional Parts of a Component by Laser-Based Free Form Heading
• 2.2.1 Laser Rod End Melting
• 2.2.1.1 Thermal Upset Process
• 2.2.1.2 Process Stages and Radiation Strategy
• 2.2.1.3 Modeling and Simulation of the Master Process
• 2.2.1.4 Energy Impact and Heat Dissipation Mechanisms
• 2.2.1.5 Solidification and Microstructure
• 2.2.1.6 Reproducibility
• 2.2.1.7 Formability
• 2.2.1.8 Linked Part Production
• 2.2.2 Laser Rim Melting
• 2.3 Rotary Swaging of Micro Parts
• 2.3.1 Introduction
• 2.3.2 Process Limitations and Measures for Their Extension
• 2.3.3 Material Flow Control
• 2.3.3.1 High Productivity in Infeed Swaging
• 2.3.3.2 High Productivity in Plunge Rotary Swaging
• 2.3.3.3 Application of External Axial Forces in Plunge Rotary Swaging
• 2.3.4 Characterization of the Material Flow with FEM
• 2.3.5 Material Modifications
• 2.3.6 Applications and Remarks
• 2.4 Conditioning of Part Properties
• 2.4.1 Introduction
• 2.4.2 Process Chain "Rotary Swaging-Extrusion"
• 2.4.2.1 Modifications of the Die Geometry
• 2.4.2.2 Modifications of Process Kinematics
• 2.4.2.3 Extrusion
• 2.4.2.4 Experimental Design
• 2.4.3 Results and Discussion
• 2.5 Influence of Tool Geometry on Process Stability in Micro Metal Forming.
• 2.5.1 Introduction
• 2.5.2 Experimental Setup
• 2.5.3 Numerical Models
• 2.5.4 Circular Deep Drawing
• 2.5.5 Deep Drawing of Rectangular Parts
• 2.5.6 Forming Limit
• 2.5.7 Change of Scatter
• References
• 3 Process Design
• 3.1 Introduction to Process Design Claus Thomy
• 3.2 Linked Parts for Micro Cold Forming Process Chains
• 3.2.1 Introduction
• 3.2.2 Design and Production Planning of Linked Parts
• 3.2.2.1 Design and Product Model of Linked Parts
• 3.2.2.2 Production Planning
• 3.2.2.3 Tolerance Field Widening
• 3.2.3 Automated Production of Linked Micro Parts
• 3.2.3.1 Handling Concept and Equipment
• 3.2.3.2 Effects Resulting from the Production as Linked Parts
• 3.2.3.3 Synchronization of Linked Parts
• 3.3 A Simultaneous Engineering Method for the Development of Process Chains in Micro Manufacturing
• 3.3.1 Introduction
• 3.3.2 Process Planning in Micro Manufacturing
• 3.3.3 Micro-Process Planning and Analysis (µ-ProPlAn)
• 3.3.3.1 Modeling View: Process Chains
• 3.3.3.2 Modeling View: Material Flow
• 3.3.3.3 Modeling View: Configuration (Cause-Effect Networks)
• 3.3.3.4 Basic Quantification of Cause-Effect Networks
• 3.3.3.5 Characterization of Local Variances
• 3.3.3.6 Simultaneous Engineering Procedure Model
• 3.3.3.7 Geometry-Oriented Modelling of Process Chains
• 3.3.3.8 Analysis and Model Optimization
• References
• 4 Tooling
• 4.1 Introduction to Tooling
• 4.2 Increase of Tool Life in Micro Deep Drawing
• 4.2.1 Introduction
• 4.2.2 Definitions
• 4.2.2.1 Tool Life
• 4.2.2.2 Dry Forming
• 4.2.3 Experimental Setups
• 4.2.3.1 Reciprocating Ball-on-Plate Test
• 4.2.3.2 Micro Deep Drawing
• 4.2.3.3 Combined Blanking and Deep Drawing
• 4.2.3.4 Lateral Micro Upsetting
• 4.2.4 Measurement Methods
• 4.2.4.1 Confocal Microscope
• 4.2.4.2 Negative Reproduction of Tool Geometry with Silicone.
• 4.2.5 Materials
• 4.2.5.1 Workpieces
• 4.2.5.2 Tools
• 4.2.5.3 Coatings
• 4.2.6 Results
• 4.2.6.1 Characteristics of Tool Wear in Micro Deep Drawing
• 4.2.6.2 Wear Behavior of Combined Blanking and Deep Drawing Dies
• 4.2.6.3 SLM Tool in Combined Blanking and Deep Drawing
• 4.2.6.4 Dry Forming Processes
• 4.2.6.5 Wear Behavior in Lateral Micro Upsetting
• 4.3 Controlled and Scalable Laser Chemical Removal for the Manufacturing of Micro Forming Tools
• 4.3.1 Process Fundamentals
• 4.3.2 LCM Machines Concepts
• 4.3.3 Influence of the Process Parameters on the Material Removal
• 4.3.3.1 Influence of the Electrolyte
• 4.3.3.2 Influence of the Material
• 4.3.3.3 Influence of the Laser Parameters
• 4.3.4 Strategies Towards a Controllable Laser Chemical Machining
• 4.3.4.1 Modeling of Laser-Induced Temperature Fields
• 4.3.4.2 Quality Control System for Laser Chemical Machining
• 4.3.5 Tool Fabrication
• 4.3.5.1 Manufacturing of Stellite 21 Micro Forming Dies
• 4.3.5.2 Other Examples of Laser Chemically Machined Micro Tools
• 4.3.6 Comparison with Other Micro Machining Processes
• 4.4 Process Behavior in Laser Chemical Machining and Strategies for Industrial Use
• 4.4.1 Introduction
• 4.4.2 Materials and Methods
• 4.4.3 Sustainable Electrolytes for LCM
• 4.4.4 Strategies for Industrial Use of LCM
• 4.4.4.1 Automatic Workpiece Alignment for JLCM
• 4.4.4.2 In-Process Monitoring and Fast Workpiece Exchange for SLCM
• 4.4.4.3 Demand-Oriented Multi-channel Flow in SLCM
• 4.5 Flexible Manufacture of Tribologically Optimized Forming Tools
• 4.5.1 Introduction
• 4.5.2 Variation, Dispersion, and Tolerance in Inverse Problems
• 4.5.3 Computational Engineering
• 4.5.3.1 Process Model with Wear on Cutting Tool
• 4.5.3.2 Numerical Implementation
• 4.5.4 Tribologically Active Textured Surfaces.
• 4.5.4.1 Micro-Milling to Generate Textured Surfaces
• 4.5.4.2 Micro-Tribological Investigation
• 4.5.4.3 Function Orientated Surface Characterization
• 4.5.4.4 Surface Micro-Contact Modeling
• 4.5.4.5 Inverse Modeling for Optimized Forming Die Manufacture
• 4.6 Predictive Compensation Measures for the Prevention of Shape Deviations of Micromilled Dental Products
• 4.6.1 Introduction
• 4.6.2 State of the Art and Aim
• 4.6.3 Applied Materials and Methods
• 4.6.4 Results
• 4.7 Thermo-Chemical-Mechanical Shaping of Diamond for Micro Forming Dies
• 4.7.1 Principles of Diamond Machining by Using Thermo-Chemical Effect
• 4.7.2 Ultrasonic Assisted Friction Polishing
• 4.7.2.1 Diamond Removal by Ultrasonic Assisted Friction Polishing Using Pure Metals
• 4.7.2.2 Experimental Results
• 4.7.3 Micro-Structuring of Single Crystal Diamond Using Ultrasonic Assisted Friction Polishing
• 4.7.3.1 Experimental Results
• 4.7.3.2 Setup for Micro-Structuring Single Crystal Diamond
• References
• 5 Quality Control and Characterization
• 5.1 Introduction to Quality Control and Characterization
• 5.2 Quality Inspection and Logistic Quality Assurance of Micro Technical Manufacturing Processes
• 5.2.1 Introduction
• 5.2.2 Optical 3D Surface Recording of Micro Parts Using DHM
• 5.2.2.1 Holographic Contouring
• 5.2.2.2 Digital Holographic Microscopy
• 5.2.3 Dimensional Inspection
• 5.2.3.1 State of the Art
• 5.2.3.2 Method
• 5.2.3.3 Verification and Measurement Results
• 5.2.4 Detection of Surface Defects
• 5.2.4.1 State of the Art
• 5.2.4.2 Methods
• 5.2.4.3 Validation
• 5.3 Inspection of Functional Surfaces on Micro Components in the Interior of Cavities
• 5.3.1 Introduction
• 5.3.1.1 Digital Holography
• 5.3.1.2 Two-Wavelength Contouring
• 5.3.1.3 Two-Frame Phase-Shifting
• 5.3.2 Experimental Alignment
• 5.3.2.1 Experimental Results.
• 5.3.2.2 Comparison with X-Ray Tomography
• 5.3.2.3 Different Batches of Material
• 5.3.3 Automatic Defect Detection
• 5.3.3.1 Preprocessing
• 5.3.3.2 Part Detection
• 5.3.3.3 Prototype Creation and Phase Unwrapping
• 5.3.3.4 Defect Detection
• 5.3.3.5 Detecting Loss of Focus
• 5.3.3.6 Results
• 5.4 In Situ Geometry Measurement Using Confocal Fluorescence Microscopy
• 5.4.1 Challenges of Optical Metrology for In-Process and in situ Measurements
• 5.4.2 Principle of Confocal Microscopy Based Measurement
• 5.4.2.1 Model Assumptions
• 5.4.2.2 Model Description
• 5.4.3 Experimental Validation
• 5.4.4 Uncertainty Characterization
• 5.5 Characterization of Semi-finished Micro Products and Micro Components
• 5.5.1 Introduction
• 5.5.2 Equipment for Testing Micro Samples
• 5.5.2.1 Mechanical Testing
• 5.5.2.2 Metallographic Investigations
• 5.5.3 Tensile Tests on Micro Samples
• 5.5.4 Endurance Tests on Micro Samples
• 5.5.5 Microstructure Analysis with EBSD on Rotary Swaged Samples
• References
• 6 Materials for Micro Forming
• 6.1 Introduction to Materials for Micro Forming
• 6.2 Tailored Graded Tool Materials for Micro Cold Forming via Spray Forming
• 6.2.1 Introduction
• 6.2.2 Production of Graded Tool Materials
• 6.2.2.1 Materials Selection
• 6.2.2.2 Spray Forming of Graded Tool Materials
• 6.2.2.3 Densification of Graded Tool Materials
• 6.2.2.4 Heat Treatment
• 6.2.3 Evaluation of the Graded Tool Materials
• 6.2.3.1 Co-spray-Formed Material
• 6.2.3.2 Successive Spray-Formed Material
• 6.2.4 Fabrication of Micro Cold Forming Tools
• 6.2.5 Performance of Micro Forming Tools
• 6.3 Production of Thin Sheets by Physical Vapor Deposition
• 6.3.1 Introduction
• 6.3.2 Methods
• 6.3.2.1 The Magnetron Sputtering Process
• 6.3.2.2 Separation of the Foils from the Substrate.
• 6.3.2.3 Continuous PVD Coating Process for Thin Substrate Foils.