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Flexible tooling for vibration-assisted microforming

Presz W., Andersen B.

Journal of Achievements in Materials and Manufacturing Engineering

2007

Vol. 21, nr 2

61-64

Purpose: Miniaturisation generates necessity of micro-parts production. Micro-scale means closer tolerances and better surface roughness. These requirements can be achieved with metal forming processes but under high pressure and sufficient relative sliding distance between tool and workpiece surface. It makes such a process proven to galling. This tendency increases with diminishing of component dimensions. It means that retarding undesirable surface phenomena with special regard to galling becomes a critical factor for microforming. Literature search and previous investigations shows that implementation of vibrations might be a solution for limitation of galling tendency in microforming. Design/methodology/approach: The group of so called "reference micro-components" has been chosen as an representation of micro-products. For these parts with FEM basic processes parameters were found. The tooling system for vibration microforming of referenced parts has been designed. Vibrations are performed with vibrators based on stacked ceramic multilayer technology assuring accurate frequency and amplitude control. Findings: The method based on static and dynamic analytical and FEM calculations of proper design of vibration assisted flexible tooling with piezo-vibrators has been found. Research limitations/implications: Proposed reference micro-components and designed system can be used for investigations of technological parameters for utilisations of microforming. Practical implications: Flexible laboratory system is designed to manufacture a wide range of microcomponents using tools vibrations for improving quality of products. After laboratory investigations it is attended to design industrial system working on same principles. Originality/value: Designed within this project flexible tooling for low frequency vibration assisted microforming seems to be original according to literature investigations.

Piezoelectric driven Micro-press for microforming

Presz W., Andersen B., Wanheim T.

Journal of Achievements in Materials and Manufacturing Engineering

2006

Vol. 18, nr 1-2

411--414

Purpose: Progressive miniaturisation generates necessity of micro-parts production also on the field of metal forming. At present small pats are produced with a big presses which were designed for manufacturing much bigger products. Further miniaturisation will not make possible to keep sufficient tolerances of products manufacturing with these standard presses. Design/methodology/approach: It is suggested to set up special technological lines for micro-parts production. Such lines would consist of micro-machines based on piezoelectric actuators. The recent development of that kind of actuators assures even up to several kilo-Newton forces and movement accuracy theoretically in atomic scale. As a step for building the line, a micro-press with piezoelectric drive is being constructed. Findings: The constructed press can work with direct actuator and can be also equipped with simple mechanical movement amplifier. Micro-indenting, micro-pressing and micro-backward extrusion were successfully carried on the press. Examples of simple sequentional and incremental micro-forming processes were also performed. Research limitations/implications: Equipping Micro-press with additional devices like x-y or x-y-z table positioning, automatic clamping and supplying systems etc. will able to extend its application to wide range of microforming processes. Practical implications: Micro-press in intention is going to be a part of industrial micro-lines for micro-product. Originality/value: The idea of building micro-parts with micro-machines standing as production micro-line seems to be quite natural but so far not realised. Presented Micro-press with original construction is another step to put this idea into reality.