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The experimental tool for micro-extrusion of metals

Piwnik J., Mogielnicki K., Gabrylewski M., Baranowski P.

Archives of Foundry Engineering

2011

Vol. 11, iss. 2 spec.

195--198

In paper the technological tools requirements, used for micro-extrusion of metals in cold and warm conditions are presented. The constructive principles for the micro-tools are also described. The influence of the size effect in a workpiece and a tool top layers roughness form on extrusion processes in microscale are showed. The tool, designed to an experimental verification of the size effect influence, in a tool roughness form, on the metal rod forward extrusion are presented. This tool is made in the form of two halves, joined together by the pegs and screws. It has bored two dies profiles with the same dimensions, the only difference is a degree of the containers roughness. That solution gives a possibility to specify the influence of the tool roughness degree on the extrusion forces, deformation process and a product quality. Described tool was designed in such a way to manufacture it with using conventional machining equipment.

The friction influence on stress in micro extrusion

Piwnik J., Mogielnicki K.

Archives of Foundry Engineering

2010

Vol. 10, iss. 1 spec.

451--454

Manufacturing of metallic parts by forming methods is industrially widespread due to high production rate, high accuracy, dimension’s and shape’s repeatability and good surface quality. The application of metal extrusion methods for the production of micro parts is possible, but there are some technological problems caused by small dimensions. Size effect is appearing. One of size effect symptom in micro extrusion, is a significant influence of rough contact between workpiece and tool while processing. In the case of rough contact without friction, material flows in the vicinity of the die surface. In order to explain more accurately a friction distribution in this area, the plastic wave friction model is proposed. This paper analyses specifications of a metal extrusion in micro scale. Using the friction model, a substitute friction shear factor mz and its influence on extrusion loading curves is determined in relationship to size of asperities.

The friction in rod forward and backward micro extrusion

Piwnik J., Mogielnicki K., Gabrylewski M., Baranowski P.

Archives of Foundry Engineering

2010

Vol. 10, iss. 1 spec.

447--450

Micro parts are increasingly applied in industry because of the trend to miniaturization every day devices. Microforming is a method of manufacturing metal micro elements using a plastic treatment. This kind of production ensures high productivity, shapes and dimensions repeatability and good surface quality. Size effect connected with small dimensions affects changes in treatment processes of micro parts. While forming in micro scale, surface roughness is size independent and does not decrease with decreasing detail dimensions. The article presents schemas for forward and backward extrusion of metal rods. Using FEM, tool’s roughness as a triangle wave has been assumed, taking into account thereby size effect. Influence of roughness on extrusion forces by comparison with traditional flat tools and constant friction shear factor m has been specified. Impact of roughness caused growth of extrusion forces while forward extruding. On the contrary, backward extrusion ensured stable required forces, regardless of a surface structure.