Cold Micro Metal Forming

This open access book contains the research report of the Collaborative Research Center “Micro Cold Forming” (SFB 747) of the University of Bremen, Germany. The topical research focus lies on new methods and processes for a mastered mass production of micro parts which are smaller than 1mm (by forming in batch size higher than one million). The target audience primarily comprises research experts and practitioners in production engineering, but the book may also be of interest to graduate students alike.

This open access book contains the research report of the Collaborative Research Center "Micro Cold Forming" (SFB 747) of the University of Bremen, Germany. The topical research focus lies on new methods and processes for a mastered mass production of micro parts which are smaller than 1mm (by forming in batch size higher than one million). The target audience primarily comprises research experts and practitioners in production engineering, but the book may also be of interest to graduate students alike. This work was published by Saint Philip Street Press pursuant to a Creative Commons license permitting commercial use. All rights not granted by the work's license are retained by the author or authors.

The miniaturization of industrial products is a global trend. Metal forming technology is not only suitable for mass production and excellent in productivity and cost reduction, but it is also a key processing method that is essential for products that utilize advantage of the mechanical and functional properties of metals. However, it is not easy to realize the processing even if the conventional metal forming technology is directly scaled down. This is because the characteristics of materials, processing methods, die and tools, etc., vary greatly with miniaturization. In metal micro forming technology, the size effect of major issues for micro forming have also been clarified academically. New processing methods for metal micro forming have also been developed by introducing new special processing techniques, and it is a new wave of innovation toward high precision, high degree of processing, and high flexibility. To date, several special issues and books have been published on micro-forming technology. This book contains 11 of the latest research results on metal micro forming technology. The editor believes that it will be very useful for understanding the state-of-the-art of metal micro forming technology and for understanding future trends.

Micro Metal Forming, i. e. forming of parts and features with dimensions below 1 mm, is a young area of research in the wide field of metal forming technologies, expanding the limits for applying metal forming towards micro technology. The essential challenges arise from the reduced geometrical size and the increased lot size. In order to enable potential users to apply micro metal forming in production, information about the following topics are given: tribological behavior: friction between tool and work piece as well as tool wear mechanical behavior: strength and formability of the work piece material, durability of the work pieces size effects: basic description of effects occurring due to the fact, that the quantitative relation between different features changes with decreasing size process windows and limits for forming processes tool making methods numerical modeling of processes and process chains quality assurance and metrology All topics are discussed with respect to the questions relevant to micro metal forming. The description comprises information from actual research and the young history of this technology branch to be used by students, scientists and engineers in industry who already have a background in metal forming and like to expand their knowledge towards miniaturization. tribological behavior: friction between tool and work piece as well as tool wear mechanical behavior: strength and formability of the work piece material, durability of the work pieces size effects: basic description of effects occurring due to the fact, that the quantitative relation between different features changes with decreasing size process windows and limits for forming processes tool making methods numerical modeling of processes and process chains quality assurance and metrology All topics are discussed with respect to the questions relevant to micro metal forming. The description comprises information from actual research and the young history of this technology branch to be used by students, scientists and engineers in industry who already have a background in metal forming and like to expand their knowledge towards miniaturization.

Editors Altan (Ohio State University), Ngaile (North Carolina University), and Shen (Ladish Company, Inc.) offer this extensive overview of the latest developments in the design of forging operations and dies. Basic technological principles are briefly reviewed in the first two chapters.

This congress proceedings provides recent research on leading-edge manufacturing processes. The aim of this scientific congress is to work out diverse individual solutions of "production at the leading edge of technology" and transferable methodological approaches. In addition, guest speakers with different backgrounds will give the congress participants food for thoughts, interpretations, views and suggestions. The manufacturing industry is currently undergoing a profound structural change, which on the one hand produces innovative solutions through the use of high-performance communication and information technology, and on the other hand is driven by new requirements for goods, especially in the mobility and energy sector. With the social discourse on how we should live and act primarily according to guidelines of sustainability, structural change is gaining increasing dynamic. It is essential to translate politically specified sustainability goals into socially accepted and marketable technical solutions. Production research is meeting this challenge and will make important contributions and provide innovative solutions from different perspectives.

60 novel approaches in metal forming are presented and explained in detail. Contributions from acknowledged international scientists representing the state-of-art in metal forming open a general view on recent results and a clear view on demands for new research initiatives.