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In the miniaturization of dimensions for sheet metal forming, the relative ratio of the surface asperities of tools and blanks to the outside dimensions becomes larger than that in the case of the conventional macroscale process. This means that the surface asperities may affect frictional behavior, so that it would also affect processing characteristics and accuracy of products. In this report, micro-deep drawing for producing cups of 700μm diameter and 20μm thickness is conducted using microtools and stainless steel foils with different surface conditions. To evaluate the effects of surface properties on micro-formability and micro-forming accuracy, punch force, surface accuracy, and the thickness strain distribution of microcups are experimentally investigated. Additionally, using a finite element (FE) model that considers surface roughness, the effect of surface roughness on formability is analyzed under different tool and material surface conditions. Results show that the global forming behavior in microforming is subjected much more intensely to tribological contact behavior, which is caused by the difference of surface asperities, than that in the case of the macroscale region. Moreover, it is shown that predominant factor over this local tribological behavior is the interaction of both tool/material surface asperities that depends on the normal load condition. |
