Polycrystalline model for FE-simulation of micro forming processes

A new polycrystal model was presented from the viewpoint of polycrystal structure of the billets considering free surface effects.In the model,the billet was divided into three portions,such as free surface portion,transition portion and internal portion.The grains in free surface portion were considered the single grains,and the anisotropy of the grains was taken into account by introducing grain orientation to explain the inhomogeneous deformation.In the transition portion,the effects of the neighbouring grains were adopted in the model.The grains in the internal portion were considered the polycrystalline material.With the developed model,the upsetting deformation process was simulated by the MSC Superform software.The scatter of the flow stress and inhomogeneous deformation was observed by analysis of the model.The comparisons show that the computational results are good agreed with the experimental results.This means that the presented model is effective.

Constitutive model for thin sheet metal with one or several grains across thickness in micro-forming

Effects of four factors on thin sheet metal flow stress were considered, including grain size d, thickness t, grain number across thickness （t/d ratio） and surface property. Surface model was adopted to quantitatively describe the effect of t/d ratio on flow stress for pure copper. It is predicted that when t/d ratio is larger than a critical value, effect of t/d ratio on flow stress can be neglected. Existence of critical t/d ratio changes the Hall-Petch relationship and evolution of flow stress with thickness. A criterion was proposed to determine critical t/d ratio. Then a comprehensive constitutive model was developed to consider all the four factors, with parameters determined by fitting experimental data of high purity Ni. The predicted results show the same tendencies with experiment results. Particularly when t/d ratio decreases, Hall-Petch relationship and evolution of true stress show varied slopes with two transition points.

Micro Extrusion of Ultrafine Grained Titanium Prepared by ECAP

Micro compression and micro extrusion experiments of ultrafine grained titanium cylindrical specimens in diameters of 4, 2, and 1 mm prepared by equal channel angular pressing（ECAP） were conducted on the micro plastic forming test machine. The effects of specimen size, grain size, deformation temperature and extrusion speed on the flow stress and forming properties of the ultrafine grained pure titanium were investigated. The flow stress of ultrafine grained pure titanium specimen decreases with decreasing specimen size. The yield limit of pure titanium with refined grain prepared by ECAP is significantly greater than that of coarse grained specimen. Also the research results show that the flow stress of specimen increases with decreasing deformation temperature and with the increase of the strain rate, and the ultrafine grained pure titanium possesses good micro forming properties at deformation temperature of 300 ℃.

The Research on Micro Electronic-Magnetic Forming of Sheet Metal

Micro channel of T2 copper were molding through electronic-magnetic forming experiments.Laser scanning confocal microscope and contourgraph were used to measure the section profile and sheet thickness.The effects of voltage,shape of channel and discharge cycles on laws of metal flow were studied.Results showed that forming depth of micro channel and thinning of sheet thickness increased as the increasing of the voltage.Mold-filling capacity of components formed by two molds with different structures had been increased when the voltage was increased.Mold with semicircle structure facilitate the material flow and the forming depth of parts was relative large.Semicircle structure was better than taper structure in mold-filling capacity.A number of small pulse discharges can improve the forming quality and deformation,but local thinning in sheet metal leads to non-uniform distribution of thickness.

Micro thermoplastic forming of a Pd-based metallic glass:theory and applications

Metallic glasses（MGs）are considered as the ideal materials for miniature fabrication because of their excellent micro thermoplastic forming ability in the supercooled liquid region.The understanding and controlling of micro filling process are fundamental for miniature fabrication and their applications,yet presently remain unresolved issues.A universal kinetic equation was proposed to describe the filling kinetics of viscous metallic glass supercooled liquid in micro molds with general cross sectional shapes by using a Pdbased MG as the modeling material and a series of potential applications based on the micro thermoplastic forming of the MG were developed.