TY - JOUR
T1 - Experimental study of water jet incremental micro-forming with supporting dies
AU - Shi, Yi
AU - Zhang, Weizhao
AU - Cao, Jian
AU - Ehmann, Kornel F.
N1 - Funding Information:
The authors would like to acknowledge National Science Foundation (Award CMMI #1234491) for supporting this research.
Publisher Copyright:
© 2019 Elsevier B.V.
PY - 2019/6
Y1 - 2019/6
N2 - Water Jet Incremental Micro-Forming (WJIMF) is a novel alternative to Single-Point Incremental Micro-Forming (SPIMF). Instead of using a rigid tool to form the sheet metal, a high-speed and high-pressure water jet is employed to induce plastic deformation. Dieless WJIMF has the capability to form a variety of shapes, but the total depth of the formed shape, which is affected by several process parameters, cannot be well controlled. To alleviate this problem, supporting dies can be used. This paper systematically studies the WJIMF process with several types of micro-machined supporting dies to produce micro-scale shell parts with designed geometries. It has been shown that the design of the toolpath has a profound impact on the final geometry of the part even with the same supporting die. The experimental results suggest that supporting dies with different geometries require unique toolpath strategies to achieve high geometric accuracy. Furthermore, it has been determined that water jet pressure plays an important role in the plastic deformation of the metal foil and that inappropriate combinations of toolpath and water jet pressure lead to buckling which is not found in macro-scale Water Jet Incremental Forming (WJIF). A numerical model in ABAQUS was developed to simulate the process and predict part geometry.
AB - Water Jet Incremental Micro-Forming (WJIMF) is a novel alternative to Single-Point Incremental Micro-Forming (SPIMF). Instead of using a rigid tool to form the sheet metal, a high-speed and high-pressure water jet is employed to induce plastic deformation. Dieless WJIMF has the capability to form a variety of shapes, but the total depth of the formed shape, which is affected by several process parameters, cannot be well controlled. To alleviate this problem, supporting dies can be used. This paper systematically studies the WJIMF process with several types of micro-machined supporting dies to produce micro-scale shell parts with designed geometries. It has been shown that the design of the toolpath has a profound impact on the final geometry of the part even with the same supporting die. The experimental results suggest that supporting dies with different geometries require unique toolpath strategies to achieve high geometric accuracy. Furthermore, it has been determined that water jet pressure plays an important role in the plastic deformation of the metal foil and that inappropriate combinations of toolpath and water jet pressure lead to buckling which is not found in macro-scale Water Jet Incremental Forming (WJIF). A numerical model in ABAQUS was developed to simulate the process and predict part geometry.
KW - Supporting dies
KW - Water jet incremental micro-forming
KW - Water jet technology
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U2 - 10.1016/j.jmatprotec.2019.01.012
DO - 10.1016/j.jmatprotec.2019.01.012
M3 - Article
AN - SCOPUS:85060435423
SN - 0924-0136
VL - 268
SP - 117
EP - 131
JO - Journal of Materials Processing Technology
JF - Journal of Materials Processing Technology
ER -